Cyclonic air treatment member and surface cleaning apparatus including the same

ABSTRACT

A surface cleaning apparatus comprising a first cyclonic cleaning stage having a first cyclone chamber and a first dirt collection chamber external to the first cyclone chamber. The first cyclone chamber has a cyclone first end, an opposed cyclone second end, a cyclone sidewall extending between the cyclone first end and the cyclone second end, a cyclone air inlet, a cyclone air outlet, a cyclone dirt outlet in communication with the first dirt collection chamber and a cyclone longitudinal axis extending from the cyclone first end to the cyclone second end. The dirt outlet comprises a plurality of apertures.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/529,430, filed Aug. 1, 2019, which is a continuation-in-partof U.S. patent application Ser. No. 16/101,770, filed Aug. 13, 2018; andis also a continuation-in-part of U.S. patent application Ser. No.16/201,649, filed Nov. 27, 2018, which itself claims priority to U.S.Provisional Patent Application No. 62/734,603, filed Sep. 21, 2018,herein incorporated by reference for all purposes.

FIELD

This application relates to the field of cyclonic air treatment membersand surface cleaning apparatus including the same.

INTRODUCTION

The following is not an admission that anything discussed below is partof the prior art or part of the common general knowledge of a personskilled in the art.

Various types of surface cleaning apparatus are known, including uprightsurface cleaning apparatus, canister surface cleaning apparatus, sticksurface cleaning apparatus, central vacuum systems, and hand carriablesurface cleaning apparatus such as hand vacuums. Further, variousdesigns for cyclonic hand vacuum cleaners, including battery operatedcyclonic hand vacuum cleaners, are known in the art.

Surface cleaning apparatus are known which utilize one or more cyclones.A cyclone has a dirt collection region. The dirt collection region maybe internal of the cyclone chamber (e.g., the dirt collection region maybe a lower end of the cyclone chamber. Alternately, the dirt collectionregion may be a separate dirt collection chamber that is external to thecyclone chamber and in communication with the cyclone chamber via a dirtoutlet. The dirt out may be a slot formed in the sidewall of a cyclonechamber or a gap provided between the end of the cyclone wall and an endof the cyclone chamber.

SUMMARY

In accordance with one aspect of this disclosure, a cyclone chamber isprovided with a dirt collection chamber that is in communication withthe cyclone chamber by an axially extending dirt outlet. The dirt outletmay have a length dimension in the axial longitudinal direction of thecyclone chamber that is greater than its width dimension in thecircumferential direction of the cyclone chamber. For example, thelength of the dirt outlet may be 2, 4, 6, 8 or 10 times or more thewidth of the dirt outlet (i.e., the width in the direction around theperimeter of the cyclone sidewall in a plane transverse to the cycloneaxis), An advantage of this design is that, as the air rotates in thecyclone chamber and dirt is disentrained, the disentrained dirt may bedeposited into a dirt collection chamber without the disentrained dirthaving to be conveyed along the cyclone sidewall to a dirt outlet at anaxial end of the cyclone chamber. Accordingly, the tendency of dirt tobe re-entrained in the air rotating in the cyclone chamber may bereduced.

In accordance with this aspect, there is provided a surface cleaningapparatus comprising an air flow path extending from a dirty air inletto a clean air outlet with a cyclone and a suction motor positioned inthe air flow path, the cyclone comprising:

-   -   (a) a cyclone chamber having a cyclone sidewall, a        longitudinally extending cyclone axis of rotation, a cyclone        first end, a cyclone second end spaced apart in a longitudinal        axial direction from the cyclone first end, a cyclone air inlet        proximate the cyclone first end, a cyclone air outlet located at        the cyclone second end and a dirt outlet, wherein the dirt        outlet has a length in the axial direction and a width in a        circumferential direction and the length is greater than the        width; and,    -   (b) a dirt collection chamber external to the cyclone chamber        and in communication with the cyclone chamber via the dirt        outlet.

In any embodiment, the length may be at least twice as long as thewidth.

In any embodiment, the length may be at least four times as long as thewidth.

In any embodiment, the dirt outlet may extend from a position proximatethe cyclone first end towards the cyclone second end.

In any embodiment, the dirt outlet may extend to a position proximatethe cyclone second end.

In any embodiment, the cyclone air inlet may be a tangential air inletterminating at an inlet port provided on the cyclone chamber sidewall.

In any embodiment, the cyclone front end may be openable wherein, whenthe cyclone front end is moved to an open position, the cyclone chamberand the dirt collection chamber may each be opened.

In any embodiment, the surface cleaning apparatus may further comprise adirt outlet insert member which is removably receivable in a portion ofthe dirt outlet adjacent the cyclone first end and the dirt outletinsert member may be opened when the cyclone front end is moved to anopen position.

In any embodiment, the surface cleaning apparatus may further comprise ascreen member having an outlet end located at the cyclone second end andthe screen member may extend to distal screen end located adjacent thecyclone first end.

In any embodiment, the distal end of the screen member may terminate0.01-0.75 inches from the cyclone first end.

In any embodiment, the distal end of the screen member may terminate0.05-0.375 inches from the cyclone first end.

In any embodiment, the cyclone air inlet may be a tangential inlethaving a conduit portion interior the cyclone chamber and the dirtoutlet may extend from a position proximate an axially inner side of theinlet conduit towards the cyclone second end.

In any embodiment, the dirt outlet may extend to a position proximatethe cyclone second end.

In any embodiment, the dirt outlet may extend from a position 0.01-0.2inches axially inwardly from the axially inner side of the inlet conduittowards the cyclone second end.

In any embodiment, the cyclone front end may be openable wherein, whenthe cyclone front end is moved to an open position, the cyclone chamberand the dirt collection chamber may each be opened.

In any embodiment, the surface cleaning apparatus may further comprise ascreen member having an outlet end located at the cyclone second end andthe screen member may extend to distal screen end located adjacent theaxially inner side of the inlet conduit.

In any embodiment, the surface cleaning apparatus may further comprise adirt outlet insert member which is removably receivable in a portion ofthe dirt outlet adjacent the cyclone first end and the dirt outletinsert member may be opened when the cyclone front end is moved to anopen position.

In accordance with another aspect of this disclosure, a cyclone chamberis provided with a dirt collection chamber that is in communication withthe cyclone chamber by two or more dirt outlet regions. The two dirtoutlet regions may be discrete outlets (i.e., each dirt outlet regionmay be a dirt outlet that is surrounded by, e.g., a portion of thesidewall of the cyclone chamber or a portion of the sidewall of thecyclone chamber and a portion of an end wall of the cyclone chamber) orthey may be contiguous (e.g., they may be connected by a gap or slotformed in the cyclone chamber sidewall so as to form a single dirtoutlet opening in, e.g., the cyclone chamber sidewall).

An advantage of this design is that dirt which is separated from the airswirling in the cyclone chamber prior to the swirling air reaching anend of the cyclone chamber opposed to the cyclone air inlet end (e.g.,after the air has turned, for example, 1 or 2 times in the cyclonechamber) may be removed from the cyclone chamber by a first dirt outletregion and the remainder of the dirt may be separated in a second dirtoutlet region that is located closer to or at the end of the cyclonechamber opposed to the cyclone air inlet end.

In accordance with this aspect, there is provided a cyclonic airtreatment member comprising:

-   -   (a) a cyclone having a cyclone sidewall, a cyclone first end, an        opposed cyclone second end, a cyclone air inlet proximate the        cyclone first end, a cyclone air outlet and a cyclone        longitudinal axis extending from the cyclone first end to the        cyclone second end, wherein a cyclone chamber is located between        the cyclone first and second ends and the cyclone chamber has an        outer perimeter which comprises the cyclone sidewall, wherein an        air flow path extends from the cyclone air inlet to the cyclone        air outlet: and,    -   (b) a dirt collection chamber external to the cyclone chamber,        the dirt collection chamber having first and second dirt outlet        regions, each dirt outlet region extending around a portion of        the perimeter of the cyclone chamber, wherein the second dirt        outlet region is positioned proximate the cyclone second end,        and the first dirt outlet region is positioned toward the        cyclone first end relative to the second dirt outlet region.

In any embodiment, the first dirt outlet region may be longitudinallyspaced apart from and discrete from the second dirt outlet region.

In any embodiment, the second dirt outlet region may be longitudinallyspaced apart from and contiguous with the first dirt outlet region.

In any embodiment, the first dirt outlet region may be angularly offsetabout the outer perimeter of the cyclone chamber as compared to thesecond dirt outlet region.

In any embodiment, at least one of the first and second dirt outletregions may comprise a slot extending angularly around a portion of theperimeter of the cyclone chamber.

In any embodiment, at least one of the first and second dirt outletregions may comprise an array of 4 or more (e.g., 4, 5, 6, 7, 8, 9 or10) apertures formed in the cyclone sidewall.

In any embodiment, the first dirt outlet region may comprise a slotformed in the cyclone sidewall, and the second dirt outlet regioncomprises an array of 4 or more (e.g., 4, 5, 6, 7, 8, 9 or 10) aperturesformed in the cyclone sidewall and positioned adjacent the first dirtoutlet region between the cyclone first end and the first dirt outletregion.

In any embodiment, each of the first and second dirt outlet regions mayhave a long dimension, and the long dimension of the first dirt outletregion is oriented generally transverse to the long dimension of thesecond dirt outlet region.

In any embodiment, the air flow path may include a cyclonic path portionthat extends cyclonically from the cyclone air inlet toward the cyclonesecond end, and at least one of the dirt outlet regions may have a longdimension that is aligned with the cyclonic path portion. At least 75%of the first dirt outlet region may extend along a portion of thecyclonic path portion. Alternately, the first dirt outlet region mayextend along the cyclonic path from an upstream outlet end of the firstdirt outlet region to a downstream outlet end of the first dirt outletregion.

In any embodiment, the downstream outlet end of the first dirt outletregion may be positioned towards the cyclone second end relative to theupstream outlet end of the first dirt outlet region.

In any embodiment, both of the upstream outlet end of the first dirtoutlet region and the downstream outlet end of the first dirt outletregion may be located along a portion of the cyclonic path portion.

In any embodiment, the second dirt outlet region may have a longdimension having a radial projection that is aligned perpendicularly tothe cyclone axis. Alternately or in addition, the first dirt outletregion may have a long dimension having a radial projection that isaligned parallel to the cyclone axis.

In any embodiment, the second dirt outlet region may be bordered by thecyclone second end.

In any embodiment, the cyclone may further comprise a third dirt outletregion to the dirt collection chamber, the third dirt outlet region isformed in the cyclone sidewall, and is oriented transverse to the firstand second dirt outlet regions. The first, second, and third dirt outletregions may be contiguous. Alternately, one, two or all three may bediscrete or one may be discrete and two may be contiguous.

In any embodiment, the cyclone air outlet may be at the cyclone secondend. Alternately, the cyclone air outlet may be at the cyclone firstend.

In accordance with another aspect, a plurality of discrete dirt outletregions (slots) are provided. The discrete outlet regions may provideenable enhanced dirt separation by the cyclone without increasing thebackpressure in the cyclone chamber.

In accordance with this aspect, there is provided a cyclonic airtreatment member comprising:

-   -   (a) a cyclone having a cyclone sidewall, a cyclone first end, an        opposed cyclone second end, a cyclone air inlet proximate the        cyclone first end, a cyclone air outlet, a dirt outlet and a        cyclone longitudinal axis extending from the cyclone first end        to the cyclone second end, wherein a cyclone chamber is located        between the cyclone first and second ends and the cyclone        chamber has an outer perimeter which comprises the cyclone        sidewall: and,    -   (b) a dirt collection chamber external to the cyclone chamber        and in communication with the cyclone chamber via the dirt        outlet,    -   wherein the dirt outlet comprises a plurality of discrete dirt        outlet regions, each of which extends at an angle to the cyclone        longitudinal axis.

In any embodiment, the plurality of dirt outlet regions may extendperpendicular ±15, 20, 25 or 30° to the cyclone longitudinal axis.

In any embodiment, the plurality of dirt outlet regions may extendgenerally perpendicular to the cyclone longitudinal axis.

In any embodiment, the plurality of dirt outlet regions may comprise aplurality of outlet slots that are arranged side by side along at leasta portion of an axial length of the cyclone.

In any embodiment, a first dirt outlet region may be positionedproximate the cyclone second end, and a remainder of the plurality ofdirt outlet regions may be positioned axially inward of the first dirtoutlet region towards the cyclone first end.

In any embodiment, the cyclone air outlet may be located at the cyclonesecond end.

In any embodiment, the cyclone air outlet may comprise a solid portionat the cyclone second end and an air permeable portion axially inwardthereof and the dirt outlet regions may be positioned only in a portionof the cyclone sidewall that is radially outward of the solid conduit.

In any embodiment, the cyclone air outlet may comprise a solid conduitportion at the cyclone second end and an air permeable portion axiallyinward thereof and the dirt outlet regions may be positioned in aportion of the cyclone sidewall that is radially outward of the solidconduit portion and air permeable portion.

In any embodiment, the dirt outlet may comprise at least three, five,seven or nine dirt outlet regions.

In any embodiment, the dirt outlet regions may be axially spaced apartfrom each other.

In any embodiment, the cyclone air inlet may be a tangential inlethaving a conduit portion interior the cyclone chamber and the pluralityof dirt outlet regions may extend from the cyclone second end to aposition axially inwards of an axially inner side of the inlet conduit.Optionally, the plurality of dirt outlet regions may extend to aposition proximate the axially inner side of the inlet conduit towardsthe cyclone second end.

In any embodiment, the cyclone air inlet may terminate at an inlet portprovided on the cyclone chamber sidewall and the plurality of dirtoutlet regions may extend from the cyclone second end towards thecyclone first end. Optionally, the plurality of dirt outlet regions mayextend to a position proximate the cyclone first end.

In any embodiment, at least one of the dirt outlet regions may havefirst and second axially spaced apart sides wherein at least one of thesides is convex or concave.

In any embodiment, at least some of the dirt outlet regions may beaxially evenly spaced apart.

In any embodiment, at least some of the dirt outlet regions may beaxially spaced apart by varying amounts.

In any embodiment, the dirt outlet regions may have an axial dirt outletwidth and the axial dirt outlet width of the dirt outlet regions maydecrease from a forward location of the cyclone at which the dirt outletregions commence to a rear location of the cyclone at which the dirtoutlet regions terminate.

In any embodiment, the dirt outlet regions may be spaced apart by anaxial distance and the axial distance may decrease from a forwardlocation of the cyclone at which the dirt outlet regions commence to arear location of the cyclone at which the dirt outlet regions terminate.

In accordance with another aspect of this disclosure, a surface cleaningapparatus is provided with a cyclone chamber having a dirt collectionchamber that is in communication with the cyclone chamber by a dirtoutlet that includes a plurality of perforations or apertures.

An advantage of this design is that the size of the apertures may reducebackpressure caused by air leaving the cyclone chamber to enter the dirtcollection chamber. Another possible advantage is that dirt particlesmay pass through the apertures into the dirt collection chamber as theyare disentrained from the air, while large debris may remain in thecyclone chamber, thereby allowing the cyclone chamber to be used as acollection chamber for large debris, increasing the dirt collectioncapacity of the surface cleaning apparatus without increasing the sizeof the surface cleaning apparatus. This is particularly advantageous fora hand held vacuum cleaner.

In accordance with this aspect, there is provided a surface cleaningapparatus comprising an air flow path extending from a dirty air inletto a clean air outlet with a first cyclonic cleaning stage and a suctionmotor positioned in the air flow path, the first cyclonic cleaning stagecomprising a first cyclone chamber and a first dirt collection chamberexternal to the first cyclone chamber, the first cyclone chamber havinga cyclone first end, an opposed cyclone second end, a cyclone sidewallextending between the cyclone first end and the cyclone second end, acyclone air inlet, a cyclone air outlet, a cyclone dirt outlet incommunication with the first dirt collection chamber and a cyclonelongitudinal axis extending from the cyclone first end to the cyclonesecond end, wherein the dirt outlet comprises a plurality of apertures.

In any embodiment, the plurality of apertures may comprise more than 10apertures.

In any embodiment, the plurality of apertures may comprise more than 20apertures.

In any embodiment, the apertures may have a width of 0.10 inches to 0.20inches.

In any embodiment, the apertures may have a width of 0.010 inches to0.10 inches.

In any embodiment, the apertures may be provided at a cyclone air outletend of the first cyclone chamber.

In any embodiment, the cyclone air outlet end may be the cyclone secondend and the cyclone air inlet may be provided at the cyclone first end.

In any embodiment, the surface cleaning apparatus may be a hand vacuumcleaner having an upper end and a lower end, the upper end may have thedirty air inlet and, when the hand vacuum cleaner is oriented with theupper end above the lower end, the apertures may be provided in a lowerportion of the cyclone sidewall.

In any embodiment, the cyclonic cleaning stage may comprise a stationaryportion and an openable portion, the openable portion may be part of thelower end of the hand vacuum cleaner and may comprise a portion of thecyclone sidewall and the openable portion may be moveably mounted by amount between a closed position in which the first cyclone chamber andthe first dirt collection chamber are closed and an open position inwhich the first cyclone chamber and the first dirt collection chamberare open and the apertures may be provided in the openable portion.

In any embodiment, when the hand vacuum cleaner may be oriented with theupper end above the lower end, the first dirt collection chamber mayunderlie the first cyclone chamber.

In any embodiment, the first cyclone chamber may have a first lateralside that extends radially outwardly from the cyclone longitudinal axisin a first direction and a second lateral side that extends radiallyoutwardly from the cyclone longitudinal axis in a second direction thatis opposed to the first direction and the apertures may be provided onlyon the first lateral side of the first cyclone chamber.

In any embodiment, the surface cleaning apparatus may further comprise asecond cyclonic cleaning stage downstream from the first cycloniccleaning stage, the second cyclonic cleaning stage may have a dirtcollection region wherein, when the hand vacuum cleaner is oriented withthe upper end above the lower end, the first dirt collection chamber andthe dirt collection region may each underlie the first cyclone chamber.

In any embodiment, the second cyclonic cleaning stage may comprise asecond cyclone chamber and a second dirt collection chamber external tothe second cyclone chamber and the second dirt collection chamber maycomprise the dirt collection region.

In any embodiment, the first cyclone chamber may have a first lateralside that extends radially outwardly from the cyclone longitudinal axisin a first direction and a second lateral side that extends radiallyoutwardly from the cyclone longitudinal axis in a second direction thatis opposed to the first direction and the apertures may be provided onlyon the first lateral side of the first cyclone chamber, the first dirtcollection chamber may be located on the first lateral side and the dirtcollection region may be located on the second lateral side.

In accordance with another aspect of this disclosure, there is provideda surface cleaning apparatus having a first air treatment stage having afirst air treatment chamber and a first dirt collection chamber, and asecond air treatment stage having a second dirt collection chamber. Thefirst dirt collection chamber and the second dirt collection chambereach underlie the first air treatment chamber.

An advantage of this design is that by positioning the dirt collectionchambers beneath the first air treatment chamber, the first and seconddirt collection chambers may be emptyable concurrently, and optionallywith emptying the first air treatment chamber. A further advantage isthat the size of the surface cleaning apparatus may be reduced sinceaccess to the second air treatment stage is not necessary to empty thesurface cleaning apparatus.

In accordance with this aspect, there is provided a surface cleaningapparatus comprising:

-   -   a) a front end, a rear end, and first and second laterally        opposed sides, each laterally opposed side extends in a        forward/rearward direction;    -   b) an air flow path extending from a dirty air inlet provided at        the front end to a clean air outlet with a suction motor        positioned in the air flow path;    -   c) a first air treatment stage positioned in the air flow path        downstream from the dirty air inlet, the first air treatment        stage comprising a first air treatment chamber and a first dirt        collection chamber external to the first air treatment chamber;        and,    -   d) a second air treatment stage positioned in the air flow path        downstream from the first air treatment stage, the second air        treatment stage comprising a second air treatment chamber and a        second dirt collection chamber external to the second air        treatment chamber,    -   wherein the first dirt collection chamber is provided on the        first lateral side and underlies the first air treatment chamber        and the second dirt collection chamber is provided on the second        lateral side and underlies the first air treatment chamber.

In any embodiment, the first air treatment chamber may have a dirtoutlet in communication with the first dirt collection chamber and thedirt outlet may comprise a plurality of apertures.

In any embodiment, the plurality of apertures may comprise more than 10apertures.

In any embodiment, the plurality of apertures may comprise more than 20apertures.

In any embodiment, the apertures may have a width of 0.10 inches to 0.20inches.

In any embodiment, the apertures may have a width of 0.010 inches to0.10 inches. It will be appreciated that a surface cleaning apparatusmay comprise any one or more aspects set out herein and may use any oneor more features of one or more of the aspects disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the described embodiments and to show moreclearly how they may be carried into effect, reference will now be made,by way of example, to the accompanying drawings in which:

FIG. 1 is a perspective view of a surface cleaning apparatus inaccordance with an embodiment;

FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. 1, inaccordance with an embodiment;

FIG. 3 is a perspective view of an air treatment member of the apparatusof FIG. 1 with a front wall and air outlet passage omitted, inaccordance with an embodiment;

FIG. 4 is a perspective view of the air treatment member of theapparatus of FIG. 1, sectioned along line 2-2 in FIG. 1, and with thefront wall and air outlet passage omitted, in accordance with theembodiment of FIG. 3;

FIG. 5 is a perspective view of the air treatment member of theapparatus of FIG. 1, sectioned along line 5-5 in FIG. 1, and with thefront wall and air outlet passage omitted, in accordance with theembodiment of FIG. 3;

FIG. 6 is a perspective view of an alternate embodiment of the airtreatment member of the apparatus of FIG. 1 with the front wall and airoutlet passage omitted, in accordance with another embodiment;

FIG. 7 is a perspective view of the alternate air treatment member ofFIG. 6, sectioned along line 2-2 in FIG. 1, and with the front wall andair outlet passage omitted, in accordance with the embodiment of FIG. 6;

FIGS. 8-21 are perspective views of the air treatment member of theapparatus of FIG. 1, sectioned along line 5-5 in FIG. 1, and with thefront wall and air outlet passage omitted, in accordance with variousembodiments;

FIG. 22 is a cross-sectional view taken along line 2-2 in FIG. 1, inaccordance with another embodiment;

FIG. 23 is a cross-sectional view taken along line 2-2 in FIG. 1, inaccordance with another embodiment;

FIG. 24 is a perspective view of an upright surface cleaning apparatusin accordance with an embodiment;

FIG. 25 is a cross-sectional view taken along line 25-25 in FIG. 24, inaccordance with another embodiment;

FIG. 26 is a perspective view of the surface cleaning apparatus of claim1 sectioned along line 2-2, in accordance with another embodiment;

FIG. 27 is a perspective view of the surface cleaning apparatus of claim1 sectioned along line 27-27, in accordance with another embodiment;

FIG. 28 is a perspective view of a surface cleaning apparatus inaccordance with another embodiment;

FIG. 29 is a perspective view of an air treatment member of theapparatus of FIG. 28, sectioned along line 29-29 in FIG. 28, inaccordance with an embodiment;

FIG. 30 is a cross-sectional view of the air treatment member of FIG.29, sectioned along line 29-29 in FIG. 28, in accordance with theembodiment of FIG. 29;

FIG. 31 is a perspective view of the air treatment member of FIG. 29with a front wall in an open position, in accordance with the embodimentof FIG. 29;

FIG. 32 is a cross-sectional view of the air treatment member of FIG.29, sectioned along line 32-32 in FIG. 28, in accordance with theembodiment of FIG. 29;

FIG. 33 is a front view of the air treatment member of FIG. 29 with thefront wall in the open position, in accordance with the embodiment ofFIG. 29;

FIG. 34 is a perspective view of the air treatment member of FIG. 29with a front wall in a partially open position, in accordance with theembodiment of FIG. 29;

FIG. 35 is a perspective view of an alternate embodiment of the airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28, in accordance with another embodiment;

FIG. 36 is a cross-sectional view of the alternate air treatment memberof FIG. 35, sectioned along line 29-29 in FIG. 28, in accordance withthe embodiment of FIG. 35;

FIG. 37 is a perspective view of the alternate air treatment member ofFIG. 35, sectioned along line 29-29 in FIG. 28, with a front wall in afirst partially open position in accordance with the embodiment of FIG.35;

FIG. 38 is a perspective view of the alternate air treatment member ofFIG. 35, sectioned along line 29-29 in FIG. 28, with a front wall in asecond partially open position in accordance with the embodiment of FIG.35;

FIG. 39 is a perspective view of an alternate embodiment of the airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28, in accordance with another embodiment;

FIG. 40 is a cross-sectional view of the alternate air treatment memberof FIG. 39, sectioned along line 29-29 in FIG. 28, in accordance withthe embodiment of FIG. 39;

FIG. 41 is a perspective view of the alternate air treatment member ofFIG. 39, sectioned along line 41-41 in FIG. 28, in accordance with theembodiment of FIG. 35;

FIG. 42 is a perspective view of an alternate embodiment of the airtreatment member of the apparatus of FIG. 28, sectioned along line 42-42in FIG. 28, in accordance with an embodiment;

FIG. 43 is a cross-sectional view of the alternate air treatment memberof FIG. 42, sectioned along line 42-42 in FIG. 28, in accordance withthe embodiment of FIG. 42;

FIG. 44 is a front view of the alternate air treatment member of FIG. 42with a front wall in an open position, in accordance with the embodimentof FIG. 42;

FIG. 45 is a perspective view of an alternate embodiment of the airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28, in accordance with another embodiment;

FIG. 46 is a cross-sectional view of the alternate air treatment memberof FIG. 45, sectioned along line 29-29 in FIG. 28, in accordance withthe embodiment of FIG. 45; and

FIG. 47 is a front perspective view of the alternate air treatmentmember of FIG. 45 with a front wall in an open position, in accordancewith the embodiment of FIG. 45;

FIG. 48 is a front perspective view of an alternate embodiment of theair treatment member of the apparatus of FIG. 28, with a front wall inan open position, in accordance with an embodiment;

FIG. 49 is a front view of the alternate air treatment member of FIG. 48with a front wall in an open position, in accordance with the embodimentof FIG. 48;

FIG. 50 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 51 is a cross-sectional view of the air treatment member of FIG.50, sectioned along line 32-32 in FIG. 28;

FIG. 52 is a perspective view of the air treatment member of FIG. 50,sectioned along line 52-52 in FIG. 28;

FIG. 53 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 54 is a cross-sectional view of the air treatment member of FIG.53, sectioned along line 32-32 in FIG. 28;

FIG. 55 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 56 is a cross-sectional view of the air treatment member of FIG.55, sectioned along line 32-32 in FIG. 28;

FIG. 57 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 58 is a cross-sectional view of the air treatment member of FIG.57, sectioned along line 32-32 in FIG. 28;

FIG. 59 is a perspective view of the air treatment member of FIG. 57,sectioned along line 52-52 in FIG. 28;

FIG. 60 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 61 is a cross-sectional view of the air treatment member of FIG.60, sectioned along line 32-32 in FIG. 28;

FIG. 62 is a perspective view of the air treatment member of FIG. 60,sectioned along line 52-52 in FIG. 28;

FIG. 63 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 64 is a cross-sectional view of the air treatment member of FIG.63, sectioned along line 32-32 in FIG. 28;

FIG. 65 is a perspective view of the air treatment member of FIG. 63,sectioned along line 52-52 in FIG. 28;

FIG. 66 is a perspective view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 29-29in FIG. 28;

FIG. 67 is a cross-sectional view of the air treatment member of FIG.66, sectioned along line 32-32 in FIG. 28;

FIG. 68 is a perspective view of the air treatment member of FIG. 66,sectioned along line 52-52 in FIG. 28;

FIG. 69 is a cross-sectional view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 32-32in FIG. 28;

FIG. 70 is a cross-sectional view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 32-32in FIG. 28;

FIG. 71 is a cross-sectional view of an alternate embodiment of an airtreatment member of the apparatus of FIG. 28, sectioned along line 32-32in FIG. 28;

FIG. 72 is a perspective view of a surface cleaning apparatus inaccordance with another embodiment, in an open position;

FIG. 73 is another perspective view of the surface cleaning apparatus ofFIG. 72;

FIG. 74 is a top perspective view of an openable portion of the surfacecleaning apparatus of FIG. 72;

FIG. 75 is a front view of the openable portion of the surface cleaningapparatus of FIG. 72

FIG. 76 is a cross-sectional perspective view of the surface cleaningapparatus of FIG. 72, sectioned along line 76-76 in FIG. 73, with theopenable portion closed;

FIG. 77 is a cross-sectional perspective view of the surface cleaningapparatus of FIG. 72, sectioned along line 77-77 in FIG. 76, with theopenable portion closed;

FIG. 78 is a cross-sectional perspective view of the surface cleaningapparatus of FIG. 72, sectioned along line 78-78 in FIG. 76, with theopenable portion closed; and,

FIG. 79 is a cross-sectional perspective view of the surface cleaningapparatus of FIG. 72, sectioned along line 79-79 in FIG. 76, with theopenable portion closed.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Numerous embodiments are described in this application, and arepresented for illustrative purposes only. The described embodiments arenot intended to be limiting in any sense. The invention is widelyapplicable to numerous embodiments, as is readily apparent from thedisclosure herein. Those skilled in the art will recognize that thepresent invention may be practiced with modification and alterationwithout departing from the teachings disclosed herein. Althoughparticular features of the present invention may be described withreference to one or more particular embodiments or figures, it should beunderstood that such features are not limited to usage in the one ormore particular embodiments or figures with reference to which they aredescribed.

The terms “an embodiment,” “embodiment,” “embodiments,” “theembodiment,” “the embodiments,” “one or more embodiments,” “someembodiments,” and “one embodiment” mean “one or more (but not all)embodiments of the present invention(s),” unless expressly specifiedotherwise.

The terms “including,” “comprising” and variations thereof mean“including but not limited to,” unless expressly specified otherwise. Alisting of items does not imply that any or all of the items aremutually exclusive, unless expressly specified otherwise. The terms “a,”“an” and “the” mean “one or more,” unless expressly specified otherwise.

As used herein and in the claims, two or more parts are said to be“coupled”, “connected”, “attached”, “joined”, “affixed”, or “fastened”where the parts are joined or operate together either directly orindirectly (i.e., through one or more intermediate parts), so long as alink occurs. As used herein and in the claims, two or more parts aresaid to be “directly coupled”, “directly connected”, “directlyattached”, “directly joined”, “directly affixed”, or “directly fastened”where the parts are connected in physical contact with each other. Asused herein, two or more parts are said to be “rigidly coupled”,“rigidly connected”, “rigidly attached”, “rigidly joined”, “rigidlyaffixed”, or “rigidly fastened” where the parts are coupled so as tomove as one while maintaining a constant orientation relative to eachother. None of the terms “coupled”, “connected”, “attached”, “joined”,“affixed”, and “fastened” distinguish the manner in which two or moreparts are joined together.

Further, although method steps may be described (in the disclosureand/or in the claims) in a sequential order, such methods may beconfigured to work in alternate orders. In other words, any sequence ororder of steps that may be described does not necessarily indicate arequirement that the steps be performed in that order. The steps ofmethods described herein may be performed in any order that ispractical. Further, some steps may be performed simultaneously.

As used herein and in the claims, two elements are said to be “parallel”where those elements are parallel and spaced apart, or where thoseelements are collinear.

Some elements herein may be identified by a part number, which iscomposed of a base number followed by an alphabetical orsubscript-numerical suffix (e.g. 112 a, or 112 ₁). Multiple elementsherein may be identified by part numbers that share a base number incommon and that differ by their suffixes (e.g. 112 ₁, 112 ₂, and 112 ₃).All elements with a common base number may be referred to collectivelyor generically using the base number without a suffix (e.g. 112).

General Description of a Hand Vacuum Cleaner

Referring to FIGS. 1-2, an exemplary embodiment of a surface cleaningapparatus is shown generally as 100. The following is a generaldiscussion of apparatus 100, which provides a basis for understandingseveral of the features that are discussed herein. As discussedsubsequently, each of the features may be used individually or in anyparticular combination or sub-combination in this or in otherembodiments disclosed herein.

Embodiments described herein include an improved cyclonic air treatmentmember 116, and a surface cleaning apparatus 100 including the same.Surface cleaning apparatus 100 may be any type of surface cleaningapparatus, including for example a hand vacuum cleaner as shown (seealso FIG. 28), a stick vacuum cleaner, an upright vacuum cleaner (100 inFIG. 24), a canister vacuum cleaner, an extractor, or a wet/dry typevacuum cleaner.

In FIGS. 1-2 and 28, surface cleaning apparatus 100 is illustrated as ahand vacuum cleaner, which may also be referred to also as a “handvac”or “hand-held vacuum cleaner”. As used herein, a hand vacuum cleaner isa vacuum cleaner that can be operated to clean a surface generallyone-handedly. That is, the entire weight of the vacuum may be held bythe same one hand used to direct a dirty air inlet of the vacuum cleanerwith respect to a surface to be cleaned. For example, handle 104 anddirty air inlet 108 may be rigidly coupled to each other (directly orindirectly), such as being integrally formed or separately molded andthen non-removably secured together (e.g. adhesive or welding), so as tomove as one while maintaining a constant orientation relative to eachother. This is to be contrasted with canister and upright vacuumcleaners, whose weight is typically supported by a surface (e.g. afloor) during use. When a canister vacuum cleaner is operated, or whenan upright vacuum cleaner is operated in a ‘lift-away’ configuration, asecond hand is typically required to direct the dirty air inlet at theend of a flexible hose.

Still referring to FIGS. 1-2 and 28, surface cleaning apparatus 100includes a main body or a handvac body 112 having an air treatmentmember 116 (which may be permanently affixed to the main body or may beremovable in part or in whole therefrom for emptying), a dirty air inlet108, a clean air outlet 120, and an air flow path 124 extending betweenthe dirty air inlet 108 and the clean air outlet 120.

Surface cleaning apparatus 100 has a front end 128, a rear end 132, anupper end (also referred to as the top) 136, and a lower end (alsoreferred to as the bottom) 140. In the embodiment shown, dirty air inlet108 is at an upper portion of apparatus front end 128 and clean airoutlet 120 is at a rearward portion of apparatus 100 at apparatus rearend 132. It will be appreciated that dirty air inlet 108 and clean airoutlet 120 may be positioned in different locations of apparatus 100.

A suction motor 144 is provided to generate vacuum suction through airflow path 124, and is positioned within a motor housing 148. Suctionmotor 144 may be a fan-motor assembly including an electric motor andimpeller blade(s). In the illustrated embodiment, suction motor 144 ispositioned in the air flow path 124 downstream of air treatment member116. In this configuration, suction motor 144 may be referred to as a“clean air motor”. Alternatively, suction motor 144 may be positionedupstream of air treatment member 116, and referred to as a “dirty airmotor”.

Air treatment member 116 is configured to remove particles of dirt andother debris from the air flow. In the illustrated example, airtreatment member 116 includes a cyclone assembly (also referred to as a“cyclone bin assembly”) having a single cyclonic cleaning stage with asingle cyclone 152 and a dirt collection chamber 156 (also referred toas a “dirt collection region”, “dirt collection bin”, “dirt bin”, or“dirt chamber”). Cyclone 152 has a cyclone chamber 154. Dirt collectionchamber 156 may be external to the cyclone chamber 154 (i.e. dirtcollection chamber 156 may have a discrete volume from that of cyclonechamber 154). Cyclone 152 and dirt collection chamber 156 may be of anyconfiguration suitable for separating dirt from an air stream andcollecting the separated dirt respectively, and may be in communicationdirt outlet(s) of the cyclone chamber.

In alternate embodiments, air treatment member 116 may include a cycloneassembly having two or more cyclonic cleaning stages arranged in serieswith each other. Each cyclonic cleaning stage may include one or morecyclones arranged in parallel with each other and one or more dirtcollection chambers, of any suitable configuration. The dirt collectionchamber(s) may be external to the cyclone chambers of the cyclones. Eachcyclone may have its own dirt collection chamber or two or more cyclonesfluidically connected in parallel may have a single common dirtcollection chamber.

Referring to FIG. 2, hand vacuum cleaner 100 may include a pre-motorfilter 160 provided in the air flow path 124 downstream of air treatmentmember 116 and upstream of suction motor 144. Pre-motor filter 160 maybe formed from any suitable physical, porous filter media. For example,pre-motor filter 160 may be one or more of a foam filter, felt filter,HEPA filter, or other physical filter media. In some embodiments,pre-motor filter 160 may include an electrostatic filter, or the like.As shown, pre-motor filter 160 may be located in a pre-motor filterhousing 164 that is external to the air treatment member 116.

In the illustrated embodiments, dirty air inlet 108 is the inlet end 168of an air inlet conduit 172. Optionally, inlet end 168 of air inletconduit 172 can be used as a nozzle to directly clean a surface.Alternatively, or in addition to functioning as a nozzle, air inletconduit 172 may be connected (e.g. directly connected) to the downstreamend of any suitable accessory tool such as a rigid air flow conduit(e.g., an above floor cleaning wand), a crevice tool, a mini brush, andthe like. As shown, dirty air inlet 108 may be positioned forward of airtreatment member 116, although this need not be the case.

In the embodiment of FIGS. 2 and 28, the air treatment member 116comprises a cyclone 152, the air treatment air inlet is a cyclone airinlet 184, and the air treatment member air outlet is a cyclone airoutlet 188. Accordingly, in operation, after activating suction motor144, dirty air enters apparatus 100 through dirty air inlet 108 and isdirected along air inlet conduit 172 to the cyclone air inlet 184. Asshown, cyclone air inlet 184 may direct the dirty air flow to entercyclone chamber 154 in a tangential direction so as to promote cyclonicaction. Dirt particles and other debris may be disentrained (i.e.separated) from the dirty air flow as the dirty air flow travels fromcyclone air inlet 184 to cyclone air outlet 188. The disentrained dirtparticles and debris may discharge from cyclone chamber 154 through adirt outlet 190 into dirt collection chamber 156 external to the cyclonechamber 154, where the dirt particles and debris may be collected andstored until dirt collection chamber 156 is emptied.

Air exiting cyclone chamber 154 may pass through an outlet passage 192located upstream of cyclone air outlet 188. Cyclone chamber outletpassage 192 may also act as a vortex finder to promote cyclonic flowwithin cyclone chamber 154. In some embodiments, cyclone outlet passage192 may include an air permeable portion 197 (which may be referred toas a screen or shroud 197, e.g. a fine mesh screen) in the air flow path124 to remove large dirt particles and debris, such as hair, remainingin the exiting air flow. As exemplified in FIG. 50, the cyclone airoutlet 188 may comprise a conduit portion 189 which is solid (airimpermeable) and an axially inward screen or shroud 197.

From cyclone air outlet 188, the air flow may be directed into pre-motorfilter housing 164 at an upstream side 196 of pre-motor filter 160. Theair flow may pass through pre-motor filter 160, and then exit throughpre-motor filter chamber air outlet 198 into motor housing 148. At motorhousing 148, the clean air flow may be drawn into suction motor 144 andthen discharged from apparatus 100 through clean air outlet 120. Priorto exiting the clean air outlet 120, the treated air may pass through apost-motor filter 176, which may be one or more layers of filter media.

Power may be supplied to suction motor 144 and other electricalcomponents of apparatus 100 from an onboard energy storage member, whichmay include, for example, one or more batteries 180 a or other energystorage device. In the illustrated embodiment, apparatus 100 includes abattery pack 180. Battery pack 180 may be permanently connected toapparatus 100 and rechargeable in-situ, or removable from apparatus 100.In the example shown, battery pack 180 is located between handle 104 andair treatment member 116. Alternatively, or in addition to battery pack180, power may be supplied to apparatus 100 by an electrical cord (notshown) connected to apparatus 100 that can be electrically connected tomains power by at a standard wall electrical outlet.

Cyclonic Air Treatment Member with Two or More Dirt Outlets ExtendingAngularly Around the Cyclone Chamber Sidewall

Embodiments herein relate to an improved cyclonic air treatment memberthat may have two or more dirt outlets, which extend around a portion ofthe perimeter of the cyclone chamber sidewall. The features in thissection may be used by themselves in any surface cleaning apparatus orin any combination or sub-combination with any other feature or featuresdescribed herein.

Within a cyclone, dirt is disentrained from a dirt laden air flow bydirecting the air flow along a cyclonic path. The cyclonic flowdirection imparts radially outward forces upon dirt particles in the airflow, whereby the dirt particles are separated from the air flow andultimately, e.g., ride against the cyclone sidewall. Dirt moved againstthe cyclone sidewall may exit from the cyclone chamber to a dirtcollection chamber through a dirt outlet.

The ability of a cyclonic flow to separate dirt particles depends inpart on the radial acceleration experienced by the dirt particles as aresult of their cyclonic velocity through the cyclone. However, thecyclonic particle velocity may slow between the cyclone air inlet andair outlet. Below a threshold cyclonic particle velocity, the separationefficiency (i.e. the percentage of dirt particles separated from thedirty air flow by the cyclone) may be substantially reduced. When avacuum cleaner operates at a high air flow rate (e.g. a ‘high powermode’ in a handvac), the cyclonic particle velocity between the cycloneair inlet and air outlet may remain well above such threshold velocity.However, when a vacuum cleaner operates at a low air flow rate (e.g. a‘low power mode’ in a handvac), the cyclonic particle velocity may fallbelow the threshold velocity at some point between the cyclone air inletand air outlet. In such a case, some of the dirt particles that havealready been disentrained may be reintrained.

Embodiments herein relate to an improved cyclone having a dirt outletthat comprises a plurality of dirt outlet regions. A first dirt outletregion may be positioned closer, along the cyclonic air flow path, tothe cyclone air inlet. The dirt outlet may have at least one additionaldirt outlet region that may be positioned closer, along the cyclonic airflow path, to the cyclone air inlet. The additional dirt outlet regionmay be positioned at a location at which the cyclonic particle velocitymay still be high enough (e.g. above the threshold velocity) to providea targeted separation efficiency, even when operating at a lower airflow rate. Thus, the additional dirt outlet may permit the apparatus tooptionally operate at a lower air flow rate with less loss of separationefficiency, all else being equal. For a handvac, this may mitigate theloss of separation efficiency when operating in a ‘low power mode’,which otherwise has an advantage of consuming less power therebyproviding a longer run-time on a single charge.

Referring to FIGS. 2-4, cyclone 152 includes a cyclone sidewall 202that, as exemplified, extends along a cyclone longitudinal axis 204between a cyclone first end 206 and a cyclone second end 208.Accordingly, cyclone chamber 154 is bounded by cyclone sidewall 202 andcyclone first and second ends 206, 208. Cyclone 152 includes atangential air inlet 184, although any air inlet may be used. As shown,air inlet 184 may be located proximate cyclone first end 206, althoughthe cyclone air inlet may be provided at other locations. Cyclone alsoincludes an air outlet 188. Cyclone air outlet 188 may be locatedproximate cyclone second end 208, such as in the illustrated uniflowcyclone configuration, or it may be located at cyclone first end 206(see, for example FIGS. 24-25). Apparatus air flow path 124 includes acyclone air flow path 212, which extends from cyclone air inlet 184 tocyclone air outlet 188.

Referring to FIGS. 3-4, cyclone 152 may include first and second dirtoutlet regions 190 ₁ and 190 ₂. Second dirt outlet region 190 ₂ may belocated proximate (e.g. at or closer to) cyclone second end 208. Forexample, second dirt outlet region 190 ₂ may be located at the cyclonesecond end 208 as exemplified in FIGS. 2 and 3. Second dirt outletregion 190 ₂ may be of any design known in the vacuum cleaner arts. Forexample, it may be a slot formed in the cyclone sidewall at the cyclonesecond end 208 as exemplified or it may be defined by a gap between thecyclone chamber sidewall and the second end wall 208 (e.g., it may be anannular opening at the end of the cyclone sidewall that faces thecyclone second end 208. First dirt outlet region 190 ₁ may be locatedaxially or longitudinally towards cyclone first end 206 relative tosecond dirt outlet region 190 ₂.

Referring to FIGS. 4-5, first dirt outlet region 190 ₁ may be providedanywhere in cyclone sidewall 202 having a longitudinal position betweencyclone first end 206 and second dirt outlet 190 ₂. For example, firstdirt outlet region 190 ₁ may be longitudinally positioned betweencyclone air inlet 184 and second dirt outlet 190 ₂. This may allow dirtthat enters cyclone 152 to exit through cyclone dirt outlet region 190 ₁while that dirt has sufficient cyclonic velocity and before that dirtwould have reached second dirt outlet region 190 ₂.

In some embodiments, first dirt outlet region 190 ₁ may be aligned witha cyclonic portion of cyclone air flow path 212 (see for example FIG.15). This allows separated dirt that is sliding on cyclone sidewall 202as it is carried along a cyclonic portion of air flow path 212 to flowinto first dirt outlet region 190 ₁, through which the dirt can exitinto dirt collection chamber 156. Accordingly, the alignment of firstdirt outlet region 190 ₁ may permit the dirt outlet region 190 ₁ tobetter interact with dirt separated during an upstream portion of thecyclone air flow path 212. Even when operating at a low air flow rate,the upstream portion of flow path 212 may yet have sufficient dirtparticle velocity to provide a high separation efficiency.

It will be appreciated that cyclone 152 may have more than first andsecond dirt outlet regions 190 ₁ and 190 ₂. For example, as exemplifiedin FIGS. 50-52, three dirt outlet regions 190 ₁, 190 ₂ and 190 ₃ may beprovided. As exemplified in FIGS. 53-54, 57-59, 60-62 and 63-65 six dirtoutlet regions 190 ₁-190 ₆ may be provided. As exemplified in FIGS.55-56, ten dirt outlet regions 190 ₁-190 ₁₀ may be provided. Asexemplified, the plurality of dirt outlet regions comprises a pluralityof discrete outlet slots that are arranged side by side along a portionof, or all of, an axial length of the cyclone.

As exemplified in FIG. 50, the dirt outlet regions 190 may be positionedonly in the portion of the cyclone chamber sidewall that is radiallyoutward of the solid conduit portion 189 of the air outlet. Alternately,as exemplified in FIG. 53, the dirt outlet regions 190 may be positionedin the portion of the cyclone chamber sidewall that is radially outwardof the solid conduit portion 189 and the screen/shroud 197 of the airoutlet.

If a plurality of dirt outlet regions is provided, they may extend fromthe rear end of the cyclone 152 (cyclone second end 208) towards thefront end (cyclone chamber first end 206) as exemplified in FIGS. 51 and54, or to the front end of the cyclone as exemplified in FIG. 56. If theair inlet is provided internal of the cyclone 152, as exemplified inFIG. 55, then the dirt outlet regions 190 may terminate at or rearwardof the downstream wall 183 of the air inlet conduit 129. Accordingly,the portion of the cyclone chamber sidewall extending forwardly ofdownstream wall 183 of the air inlet conduit 129 (section A in FIG. 55)may not have any dirt outlet regions 190.

Optionally, or in addition, if plurality of dirt outlet regions isprovided, they may be evenly axially spaced apart as exemplified inFIGS. 51, 54 and 56, or they may be spaced apart by different amounts.If the axial length of a cyclone is about 80 mm, then the axial distancebetween dirt outlet regions 190 may be 1-6 mm, 1.5-4 mm or 2-3 mm. Itwill be appreciated that, if the axial length and/or diameter of acyclone increases, then the axial distance between dirt outlet regions190 may be increased.

Still referring to FIGS. 4-5, cyclone air flow path 212 may have anaxial flow width 216 (i.e. measured parallel to longitudinal axis 204)approximately equal to an axial width 220 (i.e. measured parallel tolongitudinal axis 204) of cyclone air inlet 184. Axial flow width 216may remain generally constant between cyclone air inlet 184 and cyclonesecond end 208. Cyclone dirt outlet regions 190 may have any axial width224 suitable for allowing dirt separated from the air flow to exitcyclone chamber 154 towards dirt collection chamber 156. Preferably,axial dirt outlet width 224 ₁ (or axial width 224 of each dirt outletregion 190) is between 35% and 90% of axial air inlet width 220 (i.e.about 35% to 90% of axial air flow path width 216). A width 224 withinthis range may be large enough to permit common dirt particle sizes toexit freely through the cyclone dirt outlet region 190, and yet may notbe so large that a detrimental amount of the air flow is diverted fromcyclone chamber 154 through cyclone dirt outlet region 190.

In other embodiments, axial dirt outlet width 224 ₁ may be between 15%and 150% of axial air inlet width 220 (i.e. about 15% to 150% of axialair flow path width 216), between 25% and 125%, between 40% and 75% orbetween 50% and 60%. The lower portion of this range (e.g., 10% to 50%or 15% to 35% of axial air inlet width 220) may minimize the amount ofthe air flow that diverts through cyclone dirt outlet 190 while stillpermitting at least small dirt particles to exit. The upper portion ofthis range (e.g., 75% to 150%, 90% to 150% or 100% to 125% of axial airinlet width 220) may allow very large dirt particles to exit, although asomewhat greater amount of air flow may divert through cyclone dirtoutlet region 190.

Accordingly, if the axial length of a cyclone is about 80 mm, then theaxial dirt outlet width 240 may be 1-18 mm, 2-6 mm, 3-5, or 4 mm. Itwill be appreciated that, if the axial length and/or diameter of acyclone increases, then the axial outlet width 224 may be increased.Expressed differently, the axial dirt outlet width 224 may be 2-8%, 3-7%or 5% of the axial length of the cyclone.

The axial dirt outlet width 224 and/or axial distance between dirtoutlet regions 190 may decrease from the forward location at which thedirt outlet regions 190 commence to the rear end of the location wherethe dirt outlet regions 190 terminate.

A dirt outlet region 190 may extend around part or all of the cyclonechamber sidewall, optionally in a plane transverse to the cyclone axisof rotation. For example, a dirt outlet region 190 may extend in an arcthat extends 10-180°, 25-120°, 35-90° or 45-75° around the cyclonechamber sidewall. Each dirt outlet may have the same arc or a differentarc.

It will be appreciated that the dirt outlet regions 190 may have thesame size (e.g. width, length, and/or area) or may be differently sizedand/or differently shaped. As exemplified in FIGS. 3, 9-11, 51, 54 and56, the dirt outlet regions are rectangular in shape. Alternately, thedirt outlet regions may have rounded angularly spaced apart ends (seeFIGS. 57-59), they may be oblong (see FIGS. 60-62), they may haveconcave angularly extending walls (see FIGS. 63-65), convex angularlyextending walls (see FIG. 70) or both concave and convex angularlyextending walls (see FIGS. 67-69). Alternately, or in addition, asexemplified in FIG. 71, the axial dirt outlet width 224 of all (or some)of the dirt outlet regions 190 may be different. As exemplified, theaxial dirt outlet width 224 may decrease (or decrease continually asexemplified) from the forward most dirt outlet region 190 ₁ to therearward most dirt outlet region 190 ₅.

Alternatively, or in addition, the alignment of first dirt outlet region190 ₁ with a cyclonic portion of cyclone air flow path 212 may be suchthat at least 50%, 60%, 70%, 80%, 90% or more of the area of first dirtoutlet region 190 ₁ is coincident with (e.g., extends continuouslyalong) the cyclone air flow path 212. This may expose separated dirtparticles to first dirt outlet region 190 ₁ for an extended continuousdistance along cyclone air flow path 212, whereby the dirt particles maybe more likely to exit through first dirt outlet 190 ₁, all else beingequal.

The alignment of first dirt outlet region 190 ₁ with the cyclone airflow path 212 may be such that both an upstream end 228 of dirt outletregion 190 ₁ and a downstream end 232 of dirt outlet region 190 ₁ areeach located along a portion of the cyclone air flow path 212. Forexample, dirt outlet region 190 ₁ may extend contiguously along a partof the cyclone air flow path 212 from dirt outlet upstream end 228 todirt outlet downstream end 232.

Referring to FIG. 4, first dirt outlet region 190 ₁ may have any axialposition (i.e. with respect to cyclone longitudinal axis 204) betweencyclone first end 206 and second dirt outlet 190 ₂. In some embodiments,first dirt outlet region 190 ₁ is axially offset from cyclone air inlet184 by a distance 236 sufficient to permit at least some dirt particleswithin the air flow to separate (i.e. move outwardly to the cyclonesidewall 202) as a result of the cyclonic character of air flow path212. For example, first dirt outlet region 190 ₁ may be located at leastone turn (i.e., a 360° segment) of cyclone air flow path 212 fromcyclone air inlet 184. In the illustrated example, first dirt outletregion 190 ₁ is located just under 1.5 turns of cyclone air flow path212 from cyclone air inlet 184. Characterized another way, axialdistance 236 from cyclone air inlet 184 to dirt outlet upstream end 228,measured center-to-center may be at least equal to cyclone air inletwidth 220 (i.e. at least about cyclone air flow width 216). Moregenerally, cyclone air inlet 184 may be spaced (center-to-center) fromcyclone first end 206 by an axial distance 240 at least equal to cycloneair inlet width 220.

Cyclone dirt outlet region 190 ₁ may have any angular (i.e.circumferential) position on cyclone sidewall 202. In some embodiments,cyclone dirt outlet region 190 ₁ is angular located at a bottom end 244of cyclone sidewall 202 as shown. This location allows gravity to assistwith moving separated dirt particles through cyclone dirt outlet 190 ₁.In other embodiments, cyclone dirt outlet region 190 ₁ may be angularlyoffset from sidewall bottom end 244. Although such positions may notbenefit from gravity assistance for discharging separated dirtparticles, they may advantageously provide greater flexibility toposition cyclone dirt outlet region 190 ₁ at a distance 252 alongcyclone air flow path 212, at which cyclonic particle velocities andresidency time are optimized for separation efficiency (e.g. at thepower mode(s) provided by apparatus 100). As an example, FIGS. 6-7 showcyclone dirt outlet region 190 ₁ angularly located between sidewall topand bottom ends 248, 244. In the example shown, cyclone dirt outletregion 190 ₁ has a path distance 252 of about one turn (e.g. 360degrees) from cyclone air inlet 184.

Referring to FIG. 5, cyclone dirt outlets 190 may have any orientationthat is suitable for allowing dirt particles to exit cyclone chamber154. For example, one of cyclone dirt outlets region 190 (or both asshown) may be oriented such that they have a radial projection 256 (i.e.onto a plane 260 that includes cyclone longitudinal axis 204) whereinthe long direction is oriented transverse (e.g. perpendicular) tocyclone longitudinal axis 204. For example, a cyclone dirt outlet region190 may have a projected axis 264 that is transverse (e.g.perpendicular) to longitudinal axis 204. As shown in FIG. 4, this maypermit cyclone dirt outlet(s) region 190 to be oriented in alignmentwith cyclone air flow path 212.

FIG. 5 shows an example in which projections 256 (and projected axes264) are substantially perpendicular to cyclone longitudinal axis 204.FIGS. 8-9 show an example in which projections 256 (and projected axes264) are not perpendicular. For example, projected axes 264 may be up to30 or 45° from perpendicular with longitudinal axis 204.

FIG. 8 shows dirt outlet regions 190 having a helical orientation, whichmay be aligned with the cyclonic air flow path through cyclone chamber154. As shown, each dirt outlet region 190 has an upstream end 228located towards cyclone first end 206 relative to its downstream end232. An advantage of this design is that it can allow a greater portionof the area of dirt outlet region regions 190 to extend continuouslyalong a portion of the cyclonic air flow path in cyclone chamber 154.

FIG. 9 shows dirt outlet regions 190 having a helical orientation, whichmay be transverse (e.g. opposed to, misaligned, or counter-aligned) withthe cyclonic air flow path through cyclone chamber 154. For example, ifthe cyclonic air flow path 212 from cyclone air inlet 184 iscounterclockwise when viewed from cyclone first end 206 looking towardscyclone second end 208 as illustrated in FIG. 4, then one or both ofdirt outlet regions 190 may extend clockwise from their outlet upstreamend 228 to their outlet downstream end 232 as seen in FIG. 9 (or viceversa). An advantage of a transversely oriented dirt outlet 190 is thatit may intersect several turns of the cyclone air flow path, which mayexpose the dirt outlet 190 to dirt particles having a wider range ofresidency time and particle velocities in the cyclonic flow. This mayallow particles of different sizes sufficient time to separate from theair flow and make contact with cyclone sidewall 202. This design mayalso permit the dirt outlet region 190 to provide an effective exit fora wider range of air flow rates. Further, where the air flow path withincyclone 152 reverses direction at cyclone second end 208 to traveltowards cyclone air outlet 188 (e.g. through cyclone chamber outletpassage 192, see FIG. 2) this design may align the dirt outlet region190 with the reversed portion of the air flow path (i.e. the‘counter-flow’ portion of the air flow path).

FIGS. 10 and 11 illustrate examples in which dirt outlet region 190 ₁ isoriented differently from dirt outlet region 190 ₂. As shown, one ofdirt outlet regions 190 may have a radial projection 256 (and projectedaxis 264) that is substantially perpendicular to cyclone longitudinalaxis 204, and one of dirt outlet regions 190 may have a radialprojection 256 (and projected axis 264) that is transverse but notperpendicular to longitudinal axis 204. The illustrated examples showsecond dirt outlet region 190 ₂ having a radial projection 256 ₂ (andprojected axis 264 ₂) that is substantially perpendicular to cyclonelongitudinal axis 204, and first dirt outlet region 190 ₁ having ahelical orientation. An advantage of this design is that it allows firstdirt outlet region 190 ₁ to be positioned and oriented to provide aneffective dirt outlet for lower air flow rates, while second dirt outletregion 190 ₂ is bordered by cyclone second end 208 for discharging dirtthat passes first dirt outlet region 190 ₁ and piles against cyclonesecond end 208. In FIG. 10, first dirt outlet region 190 ₁ isillustrated with a helical orientation aligned with the cyclonic airflow path through cyclone chamber 154. In FIG. 11, first dirt outletregion 190 ₂ is illustrated with a helical orientation that istransverse (e.g. opposed, misaligned, or counter-aligned) to thecyclonic air flow path through cyclone chamber 154.

Reference is now made to FIG. 12. In some embodiments, first dirt outletregion 190 ₁ may have a long direction that may be oriented parallel(e.g. ±15° of parallel) with cyclone longitudinal axis 204. An advantageof this design it that is can allow first dirt outlet region 190 ₁ tointersect several turns of the cyclone air flow path. This allows dirtoutlet region 190 ₁ to provide an exit for dirt particles that haveexperienced a wider range of residency time and particle velocities inthe cyclonic flow. In turn, this may allow particles of different sizessufficient time to separate from the air flow and make contact withcyclone sidewall 202. This design may also permit the dirt outlet region190 to provide an effective dirt outlet for a wider range of air flowrates. As shown, first dirt outlet region 190 ₁ may have a radialprojection 256 ₁ (and projected axis 264 ₁) that is parallel to cyclonelongitudinal axis 204.

FIG. 13 shows an embodiment in which the long direction of first dirtoutlet region 190 ₁ has an orientation that is between a transverse anda parallel orientation relative to cyclone longitudinal axis 204. Suchan orientation may provide a balance between (i) providing some degreeof alignment with the cyclonic air flow path through cyclone chamber 154in one of the forward direction (i.e. from cyclone first end 206 towardscyclone second end 208) or the reverse direction (i.e. from cyclonesecond end 208 towards cyclone first end 206), and (ii) exposing thedirt outlet 190 ₂ to several turns of the cyclonic air flow path.

Reference is now made to FIGS. 14-16. As shown, some embodiments ofcyclone 152 may have first dirt outlet region 190 ₁ contiguous withsecond dirt outlet 190 ₂. Accordingly, as opposed to, e.g., FIG. 13wherein two discrete outlet slots are provided, a single outlet slot oropening or gap in the sidewall may be provided which comprises two ormore dirt outlet regions. An advantage of this design is that it mayprovide, where the first and second dirt outlet regions 190 ₁ and 190 ₂meet, an outlet region having a large outlet width and length, which canaccommodate especially large dirt particles. In the illustrated example,the first and second dirt outlet regions 190 ₁ and 190 ₂ have differentorientations relative to cyclone longitudinal axis 204. As shown, firstdirt outlet region 190 ₁ may have a downstream end 232 that is connectedto second dirt outlet region 190 ₂. Downstream end 232 may be positionedtowards cyclone second end 208 relative to cyclone first end 206. Thismay provide the combination of dirt outlet regions 190 ₁ and 190 ₂ witha “T-shape” configuration. As shown in FIG. 14, first dirt outlet region190 ₁ may be oriented substantially parallel to cyclone longitudinalaxis 204. As shown in FIGS. 15-16, first dirt outlet region 190 ₁ mayhave a curved shape that is oriented neither parallel nor perpendicularto cyclone longitudinal axis 204.

Referring to FIGS. 17-19, cyclone 152 may have three dirt outlet regions190 in some embodiments. As shown, third dirt outlet region 190 ₃ may beoriented transverse to first and second dirt outlet regions 190 ₁ and190 ₂. First and second dirt outlet regions 190 ₁ and 190 ₂ may beoriented the same (as shown), or differently from each other. Anadvantage of this design is that it may permit (i) first dirt outletregion 190 ₁ to be oriented best to provide an exit for dirt particleswhen operating at low air flow rates, (ii) second dirt outlet region 190₂ to provide an exit for particles that reach cyclone second end 208,and (iii) third dirt outlet region 190 ₃ to interact with several turnsof the cyclonic air flow path, which as discussed above may provide anexit for dirt particles that have experienced a wider range of residencytime and particle velocities in the cyclonic flow, allow particles ofdifferent sizes sufficient time to separate from the air flow and makecontact with cyclone sidewall, and/or provide an effective dirt outletfor a wider range of air flow rates.

As shown, the combination of dirt outlet regions 190 ₁, 190 ₂, 190 ₃ mayhave an “H-shape” or “N-shape” configuration. In the illustratedembodiment, third dirt outlet region 190 ₃ is contiguous with first andsecond dirt outlets 190 ₁ and 190 ₂. As exemplified, third dirt outlet190 ₃ has an upstream end 228 ₃ connected to first dirt outlet region190 ₁, and a downstream end 232 ₃ connected to second dirt outlet region190 ₂. In alternative embodiments, third dirt outlet region 190 ₃ may bespaced apart from (e.g. discontiguous with) one or both of first andsecond dirt outlet regions 190 ₁, 190 ₂ such that two or 3 discreteoutlets are provided. FIG. 17 shows an example in which third dirtoutlet region 190 ₃ is oriented parallel to cyclone longitudinal axis204. FIGS. 18-19 show examples in which third dirt outlet region 190 ₃is oriented non-parallel to cyclone longitudinal axis 204 (e.g. neitherperpendicular nor parallel to cyclone longitudinal axis 204, as shown).

In other embodiments, first dirt outlet region 190 ₁ may be spaced apartfrom (e.g. discontiguous with) second dirt outlet 190 ₂, as illustratedin the examples of FIGS. 3-13.

Referring to FIG. 4, any or all of dirt outlet regions 190 may be formedin cyclone sidewall 202. For example, a dirt outlet 190 may include anaperture (e.g. hole or slot) in cyclone sidewall 202 that allowsseparated dirt particles to exit cyclone chamber 154 towards dirtcollection chamber 156. In the illustrated example, dirt outlet regions190 are formed in a portion of cyclone sidewall 202 that is common todirt collection chamber 156. An advantage of this design is that itprovides the shortest travel distance from dirt outlet 190 to dirtcollection chamber 156, which may mitigate dirt particles collecting inan intervening passage. However, in alternative embodiments dirt outletregion 190 may provide an entrance to a passage leading to dirtcollection chamber 156. This may provide greater flexibility in thelocation of dirt collection chamber 156 relative cyclone chamber 154,such as to optimize apparatus 100 for compactness. Embodiments having adirt outlet passage are discussed below.

FIG. 4 shows an example in which dirt outlet regions 190 are formed asslots in cyclone sidewall 202 (e.g., an open having a long dimensionthat extends circumferentially around a portion of the sidewall). Asshown in FIG. 20, a dirt outlet region 190 may be formed as an array of4 or more closely arranged discrete apertures 268 that collectivelydefine the dirt outlet region 190. As compared to a slot, an array ofapertures 268 may provide many smaller apertures that are discontiguouswith each other. This may help to reduce the amount of the air flowwhich diverts into dirt collection chamber 156, which in turn may reducethe backpressure and re-entrainment of collected dirt that can resultfrom such divergence. A dirt outlet region 190 may be composed of anarray of 4 or more (e.g., 5, 6, 7, 8, 9 or 10) closely arrangedapertures 268 organized in any pattern. In the illustrated embodiment,each dirt outlet region 190 is formed as 4 equally sized apertures 268arranged linearly in a single row. In other embodiment, each dirt outletregion 190 may be formed from more than 4 apertures, which may be thesame or differently sized, and which may be arranged in one or many rows(or in a different non-linear pattern). It is expressly contemplatedthat any embodiment described or shown herein as a slot may also beformed in another embodiment as an array of apertures.

Cyclonic Air Treatment Member with a Plurality of Apertures

Embodiments herein relate to an improved cyclonic air treatment memberthat may have a plurality of small dirt outlets, which may be referredto as “apertures” or “perforations”. The features in this section may beused by themselves in any surface cleaning apparatus or in anycombination or sub-combination with any other feature or featuresdescribed herein. For example, a cyclone may have a plurality ofapertures as well as one or more slots as described herein. If acombination of a slot and apertures are used, the apertures may beprovided in one or more group of apertures, and one or more groups ofapertures may be provided at or proximate a location of the slot orspaced therefrom. If a combination of slots and apertures are used, theapertures may be provided in one or more group of apertures, and one ormore groups of apertures may be provided at or proximate a location ofeach slot or spaced therefrom. For example, a group of apertures may bepositioned between a pair of spaced apart slots. Alternately, a cyclonemay have only a plurality of apertures as the dirt outlet.

As exemplified in FIGS. 21-22, in some embodiments cyclone 152 includesone or more groups 272 of small apertures 274 (e.g. 10 or more apertures274) adjacent one or more (or all) of dirt outlet regions 190. Forexample, a group 272 may be located towards cyclone first end 206relative to the adjacent dirt outlet region 190 (e.g. upstream of theadjacent dirt outlet region 190). Aperture group 272 may provide an exitfor small dirt particles which remain open in the event that theadjacent dirt outlet region 190 becomes clogged. As shown, each group272 may be angularly aligned (e.g. circumferentially aligned) with itsrespective adjacent dirt outlet region 190. The illustrated embodimentshows a first group 272 ₁ of apertures adjacent dirt outlet region 190 ₁and located between first dirt outlet region 190 ₁ and cyclone first end206, and a second group 272 ₂ of apertures adjacent dirt outlet region190 ₂ and located between second dirt outlet 190 ₂ and first dirt outlet190 ₁. As shown, first group 272 ₁ may be axially spaced from first end206 and second group 272 ₂ may be axially spaced from first dirt outlet190 ₁. FIG. 23 shows an alternative embodiment in which second groupextends from proximate second dirt outlet region 190 ₂ to proximatefirst dirt outlet 190 ₁.

Returning to FIG. 21, each aperture 274 may have a size (e.g. width,length, and/or area) that is substantially smaller than the associatedadjacent dirt outlet region 190. In some embodiments, aperture 274 mayhave a width 288 of between 0.10 inches to 0.20 inches. This may providea size that accommodates most small dirt particles collected in domestic(e.g. residential and commercial) environments. More generally,apertures 274 may each have a width 288 of between 0.010 inches and0.500 inches. Apertures 274 having a width 288 of between 0.010 inchesand 0.10 inches may provide exits suitable for very fine particles, andmay minimize the amount of the air flow that diverts from the cyclonechamber 154 through apertures 274. Apertures 274 having a width 288 ofbetween 0.20 inches and 0.50 inches may provide exits suitable forrelatively larger particles, although somewhat more of the air flow maydivert from cyclone chamber 154 through apertures 274. This may providean acceptable trade-off where the dirt particles targeted for collectionby apparatus 100 tend to be larger.

As exemplified in FIGS. 72-79, in some embodiments, the cyclone chamber154 may include dirt outlet that is a group of small apertures 272. Itwill be appreciated that there may be any number of apertures 274 in thegroup of apertures 272. For example, the group of apertures 272 may have10, 20, 30, or more apertures 274. As exemplified, the group of smallapertures 272 may be in communication with the dirt collection chamber156 such that a separate dirt outlet region 190 is not needed totransfer dirt from the cyclone chamber 154 to the dirt collectionchamber 156. It will be appreciated that by using only apertures as thedirt outlet, larger dirt particles and elongate material (e.g., hair)will be retained in the cyclone chamber 154. Accordingly, cyclonechamber 154 may function as a dirt collection chamber provided thatscreen 197 has openings therein which inhibit dirt remaining in cyclonechamber 154 from exiting via the cyclone air outlet.

As described previously, it will be appreciated that the group ofapertures 272 may be positioned anywhere within the cyclone chamber 154.For example, the apertures 274 may be positioned at the cyclone airoutlet end of the cyclone chamber 154. The cyclone air outlet end may beprovided at the cyclone second end 206, while the cyclone air inlet maybe provided at the cyclone first end 208.

In some embodiments, as described previously, the apertures 274 may beprovided in a lower portion of the cyclone sidewall. Positioning theapertures 274 in the lower portion of the cyclone sidewall may allowgravity to assist with the removal of dirt from the cyclone chamber 154.As exemplified in FIGS. 72-79, the dirt collection chamber 156 mayunderlie the cyclone chamber 154, such that particles that exit thecyclone chamber 154 by passing through the cyclone sidewall 202, throughthe apertures 274, and into the dirt collection chamber or chambers 156that may underlie the cyclone chamber 152.

In some embodiments, the surface cleaning apparatus 100 may include asecond stage cyclone 152 ₂ downstream from the first stage cyclone 152₁. It will be appreciated that each of the cyclone stages may includeone or more cyclones in series and/or in parallel. The first stagecyclone 152 ₁ may be in communication with the second stage cyclone 152₂ such that air exits the first stage cyclone 152 ₁ and enters thesecond stage cyclone chamber 154 ₂ of the second stage cyclone 152 ₂.

As described previously, the surface cleaning apparatus 100 may have adirt collection chamber 156. In some embodiments, the dirt collectionchamber 156 may collect dirt from one or more cyclones of a singlecyclonic stage or different cyclonic stages. For example a dirt chamber156 may collect dirt from the first stage cyclone 152 ₁ and the secondstage cyclone 152 ₂. Alternately, each cyclonic stage may have one ormore dirt collection chambers. For example, as exemplified in FIGS.72-79, a surface cleaning apparatus may have two or more cyclonicstages, each of which comprises one or more cyclones and one or moredirt collection chambers 156. As exemplified, the first stage cyclone152 ₁ is in communication with a first dirt collection chamber 156 ₁ andthe second stage cyclone 152 ₂ is in communication with a second dirtcollection chamber 156 ₂. As exemplified. the dirt collection chambers156 ₁ and 156 ₂ are external to the cyclone chambers.

It will be appreciated that all or a portion of each of the first dirtcollection chamber 156 ₁ and the second dirt collection chamber 156 ₂may underlie a cyclone chamber. As exemplified in FIGS. 72-79, all or aportion of each of the first dirt collection chamber 156 ₁ and thesecond dirt collection chamber 156 ₂ may underlie cyclone chamber 154.Accordingly, for example, the cyclone chamber 154 may have a firstlateral side 320 that extends radially outwardly from centrallypositioned cyclone longitudinal axis 204 in a first direction (e.g., theright side when viewed from the front as shown in FIG. 75) and a secondlateral side 322 that extends radially outwardly from the cyclonelongitudinal axis 204 in a second direction opposed to the firstdirection (e.g., the left side when viewed from the front as shown inFIG. 75).

As exemplified, the first dirt collection chamber 156 ₁ may bepositioned on the first lateral side 320, while the second dirtcollection chamber 156 ₂ may be positioned on the second lateral side322. The two chambers 156 ₁, 156 ₂ may be separated by a partition 324.The partition 324 may also be used to separate the first lateral side320 from the second lateral side 322. As exemplified in FIGS. 72-29, allof the first dirt collection chamber 156 ₁ underlies the first cyclonechamber 154 ₁ and the forward portion of the second dirt collectionchamber 156 ₂ (which comprises a majority of the volume of the seconddirt collection chamber) may underlie the first cyclone chamber 154 ₁.

It will be appreciated that the apertures 272 may be positioned on thefirst lateral side 320, the second lateral side 322, or both, dependingupon the dirt collection chamber with which they communicate. In theembodiment exemplified in FIG. 75, the first stage cyclone 152 ₁ islocated on the first lateral side 320 and the apertures 272 are locatedonly on the first lateral side 320, as exemplified in FIGS. 72-79 andmore clearly shown in FIG. 76. Positioning the apertures 272 only on thefirst lateral side 320 enables the apertures to only communicate withthe first stage cyclone 152 ₁. Accordingly, it will be appreciated thatthe apertures of the first stage cyclone chamber may be provided at anylocation which enables the apertures to communicate only with the firststage cyclone 152.

As described above, the group of apertures 272 in the first cyclonechamber 154 ₁ may be positioned on the first lateral side 320.Accordingly, when the surface cleaning apparatus 100 is in operation,dirt separated in the first cyclone 152 ₁ and of a size to pass throughthe apertures 274 may exit the first cyclone chamber 154 ₁ through theapertures 274 and may enter the first dirt chamber 156 ₁. Dirty air maypass downstream from the first stage cyclone 152 ₁ into the second stagecyclone 152 ₂. The second stage cyclone 152 ₂ may separate dirt from theair, depositing dirt in the second dirt collection chamber 156 ₂, whichis located on the second lateral side 322. As exemplified, the surfacecleaning apparatus is a hand vacuum cleaner which, in use, may be angledwith the dirty air inlet 108 angled downwardly. Therefore, in use, dirtwill tend to travel to a forward portion of each of the dirt collectionchambers 156.

Dirt that is larger than apertures 274 and smaller than the openings ofthe cyclone air outlet will remain in the first cyclone chamber 154 ₁,and, accordingly, first cyclone chamber 154 ₁ is used as a dirtcollection chamber. As exemplified in FIGS. 72-79, the surface cleaningapparatus 100 is a hand vacuum cleaner. Using the first stage cyclonechamber 154 ₁ as a dirt collection chamber may allow for the reductionin size of the hand vacuum cleaner 100 while maintaining the storagecapacity.

Optionally, the dirt collection chambers 156 ₁ and 156 ₂ areconcurrently emptyable, optionally concurrent with emptying the firststage cyclone chamber 154. Accordingly, each of the dirt collectionchambers 156 ₁ and 156 ₂ may have an openable end that are openedconcurrently. Alternately, or in addition, the first stage cyclonechamber 154 may have a portion that opens by itself or concurrently withone or both of the dirt collection chambers 156 ₁ and 156 ₂.

As exemplified in FIGS. 72 and 73, the first cyclone 152 ₁ has anopenable front. As exemplified, the first cyclone 152 ₁ has a stationaryportion 330 and an openable portion 332 and the openable portion 332 ismoveably mounted by a mount 334. As exemplified, the openable portion332 may be a part of the lower end of the surface cleaning apparatus100. For example, the mount 334 may be a hinge and/or pivot. Theopenable portion 332 may be movable between a closed position (see forexample FIGS. 76-79), in which the first cyclone chamber 154 ₁ and thefirst dirt collection chamber 156 ₁ are closed, and an open position, inwhich the first cyclone chamber 154 ₁ and the first dirt collectionchamber 156 ₁ are open (see for example FIGS. 72 and 73).

Optionally, as exemplified, the openable portion 332 includes a portionof the cyclone sidewall 202 (e.g., the sidewall may be part of each ofthe openable and stationary portions).

Each of the dirt collection chambers has a port 158, which asexemplified may be at the front end of the openable portion (e.g., theymay be provided in a front face 336 thereof). Accordingly, during use,the openable portion 332 may be opened (e.g., it may be rotated so thatfront face 336 faces downwardly. In this orientation the contents of thefirst dirt collection chamber 156 ₁, and the second dirt collectionchamber 156 ₂ may concurrently be emptied, such as under the influenceof gravity. If cyclone chamber 154 opens concurrently with the dirtchambers, then the cyclone chamber the first cyclone chamber 154 ₁, thefirst dirt collection chamber 156 ₁ and the second dirt collectionchamber 156 ₂ may be concurrently emptied by orienting the moveableportion such that front face 366 faces downwardly.

Cyclonic Air Treatment Member with One or More Dirt Outlets ExtendingAxially on the Cyclone Chamber Sidewall

Embodiments herein relate to an improved cyclonic air treatment memberthat may have one or more dirt outlets which extend in a generally axialdirection along at least a portion of the cyclone chamber sidewall. Thefeatures in this section may be used by themselves in any surfacecleaning apparatus or in any combination or sub-combination with anyother feature or features described herein.

As discussed previously, FIGS. 14-19 exemplify embodiments wherein aportion of the dirt outlet extends axially or generally axially. Inaccordance with the feature discussed in this section, and asexemplified in FIGS. 28-34, a cyclone 152 may have one or more dirtoutlets 190, each of which extends axially or generally axially.Accordingly, the dirt outlet may not include a portion that extendsangularly around the cyclone chamber sidewall as discussed previously.

As exemplified in FIGS. 29 and 30, dirt outlet 190 may have a length 224that extends linearly in the axial direction generally parallel to thecyclone axis 204. Alternately, similar to outlet 190 ₁ of FIGS. 15 and16 and outlet 190 ₃ of FIGS. 18, 19 the dirt outlet 190 may extend in adirection that is offset or slightly offset from the direction of thelongitudinal axis 204, e.g. by ±about 20° or ±10°. The dirt outlet 190may extend linearly as exemplified in FIGS. 29 and 30 or angularly assimilar to outlet 190 ₁ of FIGS. 15 and 16 and outlet 190 ₃ of FIGS. 18,19.

The dirt outlet 190 has a transverse width 226 that extends in acircumferential direction of the cyclone chamber 154. As shown in theexample of FIG. 32, the length 224 is greater than the width 226 (e.g.,the length 224 may be 5, 10, 15 or 20 times the width 226). As the airrotates within a cyclone chamber, the air will tend to stay in a band.The band may have an axial length about the axial length of a tangentialair inlet. Accordingly, the dirt outlet 190 may have an axial lengththat is at least as long as the axial length of a tangential cycloneinlet, which may allow the dirt outlet 190 to underlie the axial lengthof an entire band of air in a turn of the cyclonic air flow path throughcyclone chamber 154. If the axial length of the dirt outlet is longer,then the dirt outlet 190 may underlie more than one turn of the air,e.g., it may underlie 1.5 or 2 turns of the air.

In some embodiments, as exemplified in FIGS. 28-34, the cyclone dirtoutlet may be formed as an opening or gap in the cyclone chambersidewall 202. In the illustrated embodiment, dirt outlet 190 is formedas a rectangular aperture in the sidewall 202. In alternativeembodiments, dirt outlet 190 may have other shapes (e.g. elliptical,triangular, irregular shapes) in which the length 224 is greater thanthe width 226.

In some embodiments, the dirt outlet 190 is provided at a bottom end 244of cyclone sidewall 202 as shown. This may help dirt which remains inthe cyclone chamber 154 after termination of operation of the vacuumcleaner 100 to fall into the dirt collection chamber 156 when the vacuumcleaner 100 is held with the cyclone 152 extending horizontally (andpossibly slightly upwardly).

The dirt outlet extends between dirt outlet first or upstream end 193and dirt outlet second or downstream end 194. The dirt outlet upstreamend 193 may be located at any location along the axial length of thecyclone 152. For example, as exemplified in FIG. 31, the dirt outletupstream end 193 may be located at the front end of the cyclone 152(cyclone first end 206). Alternately, as exemplified in FIG. 47, thedirt outlet upstream end 193 may be located axially inwardly from thefront end of the cyclone 152. For example, the dirt outlet upstream end193 may be located at or axially inwardly (rearwardly) from the axiallyinner extent of the cyclone air inlet (see, e.g., FIG. 46). As shown inFIGS. 28-34, the cyclone air inlet 184 includes a conduit 129 thatextends into, and is located interior to the cyclone chamber 154. Theopen portion of the dirt outlet 190 may extend from a position locatedat or, e.g., about 0.01-0.2 inches axially inward from the axially innerside 185 of the air inlet conduit 129 towards the cyclone second end208.

Similarly, the dirt outlet downstream end 194 may be located at anylocation along the axial length of the cyclone 152. For example, thedirt outlet downstream end 194 may be located at the rear end of thecyclone 152 (cyclone second end 208). Alternately, as exemplified inFIG. 30, the dirt outlet downstream end 194 may be located axiallyinwardly from the rear end of the cyclone 152. For example, the dirtoutlet downstream end 194 may be located at passage second end 276 oraxially inwardly (forwardly) from the axially inner extent of the solidportion of the outlet passage 192 (see, e.g., FIG. 30).

Accordingly, the dirt outlet 190 may be provided by an axially extendingslot 191, which is formed in the sidewall 202, which extendslongitudinally along at least a portion of the cyclone chamber 154 in adirection generally parallel to the cyclone axis 204 between dirt outletupstream end 193 and dirt outlet downstream end 194. As exemplified inFIGS. 29-31, the length 225 of slot 191 may be greater than the openlength 224 of the dirt outlet 190. This may occur if, for example, theslot extends forwardly of the cyclone air inlet. In such a case, aninsert member 230 may be provided to limit the forward extent of theslot 191 when the surface cleaning apparatus is in operation (i.e., thelength of the slot 191 may be reduced due to insert member 230 toprovide a dirt outlet upstream end 193 that is positioned at a selectedforward extent of the cyclone 152).

FIGS. 29-31 exemplify an embodiment wherein the slot 191 extends from aposition at the cyclone first end 206 rearward towards the cyclonesecond end 208. In this embodiment, the second end 194 of the slot 191is axially spaced apart from the first end 193 and is located inwardly(forwardly) of the cyclone second end 208. As shown in FIG. 30, the slot191 is positioned under cyclone air inlet 184. Accordingly, air enteringthe cyclone 152 at the axial location of the cyclone air inlet 184(i.e., between the forward and rearward extent of) could enter the slot191.

Optionally, as exemplified, an insert member 230 may be provided, andmay be removably received in a slot portion 231 of the slot 191proximate the cyclone first end 206 as shown. When the insert member 230is received in the slot 191, the insert member 230 can occupy the slotportion 231 and prevent dirt from exiting the cyclone chamber 154 viaslot portion 231. The open portion of the dirt outlet 190 may thusextend between the second end 194 and an open outlet end 195. As aresult, in operation the open length 224 of the dirt outlet 190 may beless than the overall length 225 of the slot 191.

The insert member may extend from the front end 206 of the cyclonerearwardly any desired amount. As exemplified in FIGS. 29-31, the openoutlet end 195 may be positioned proximate an axially inner side 185 ofthe tangential air inlet 184. Accordingly, the insert member may extendinwardly to a position at the location of the axially inner side 185and, optionally, rearwardly thereof (see for example FIG. 35).

As exemplified in FIG. 2, in some embodiments, first end 280 of passage192 may be solid (i.e., it may not be porous). In such a case, theinsert member 230 may extend to the inner end of the solid portion ofscreen 197, and, optionally, rearwardly thereof such that the openoutlet end 195 may be spaced axially inwardly (towards cyclone secondend 208) from the axially inner side 185. Alternately, if the solidportion of screen 197 extends to the front end 206 of the cyclone, thenan insert member 230 may not be provided.

Alternately, the passage first end 280 may be positioned longitudinallyadjacent to the inner side 185 of the air inlet 184. If the cyclone airinlet 184 is provided inside the cyclone chamber 154, then the cycloneoutlet passage 192 may extend to a position longitudinally adjacent(e.g., within 0.01, 0.05, 0.1 or 0.125 inches) to the end 185 of thetangential inlet 184 closest to the outlet end of the cyclone chamber154.

As shown in FIG. 30, the passage first end 280 can be axially spacedinwardly from the inner side 185 of air inlet conduit 129. For example,the first end 280 of the cyclone outlet passage 192 may terminate atabout 0.01-0.75 or about 0.05-0.375 inches inwardly from the inner side185 of the air inlet 184 in some embodiments. Alternately, in someembodiments, the first end 280 of the cyclone outlet passage 192 mayabut the downstream wall 183 of the air inlet conduit 129.

As discussed subsequently, in some embodiments, the cyclone outletpassage 192 may be tapered between the passage second end 276 and thepassage first end 280. As shown in FIG. 30, the transverse width of thecyclone outlet passage 192 may increase gradually between passage firstend 280 and passage second end 276. This may provide a greater radialdistance between the cyclone chamber sidewall 202 and the cyclone outletpassage 192 at the air inlet end of the cyclone chamber 154 therebyinhibiting dirt from contacting the screen 197 as it enters the cyclonechamber 154.

In some embodiments, the cyclone first end 206 may be openable. As shownin FIG. 31, the cyclone first end 206 may be defined by an openablefront wall 207. The front wall 207 may be movable between a closedposition (shown for example in FIGS. 28-30) and an open position (shownin FIG. 31). As illustrated, when the front end 206 is moved to the openposition, the cyclone chamber 154 and the dirt collection chamber 156are each opened. This may facilitate emptying dirt and debris from thecyclone 152.

Alternately or in addition, the cyclone chamber 154 and dirt collectionchamber 156 may be separately openable.

As exemplified in FIG. 31, if an insert member 230 is provided, then theinsert member 230 can be mounted to the front wall 207. Accordingly, asthe cyclone front end 206 is moved to the open position, the insertmember can be removed from the dirt outlet portion 231. This may provideadditional access to dirt collection chamber 156 to facilitate emptying.

As shown, the cyclone outlet passage 192 can be tapered. The reductionin width of the passage 192 moving from the second end 176 to the firstend 280 may allow the insert member 230 to have a greater axial lengthwhile still permitting the insert member 230 to be withdrawn from thedirt outlet slot 191.

It will be appreciated that, instead of providing an insert member 230to close part of slot 191, slot 191 may have the same dimensions as dirtoutlet 190. Such an embodiment is exemplified in FIGS. 45-47, whereinthe cyclone 152 is not provided with an insert member 230. Rather, asexemplified, the dirt outlet 190 may be defined entirely by a gap/slot191 in the cyclone chamber sidewall 202. The cyclone chamber sidewall202 may include a section 203 that extends from proximate the front end206 to the dirt outlet first end 193. A gap 191 in the sidewall 202extending rearward from the dirt outlet first end 193 (the open outletend 195) may then define the dirt outlet 190. Accordingly, the dirtoutlet first end 193 can be positioned at the same location as discussedwith respect to the open outlet end 195, i.e., it may be positionedproximate to the second end 185 of the tangential air inlet 184.

FIGS. 35-38 exemplify an embodiment wherein the open portion of the dirtoutlet 190 is axially spaced apart (inwardly) from the second end 185 ofthe air inlet 184 towards the cyclone second end 208. This may alsoreduce the re-entrainment of collected dirt from the dirt collectionchamber 156, particularly if outlet passage 192 is not tapered.

In the example shown in FIGS. 35-38, the insert member 230 extendsaxially from the cyclone first end 206 towards the cyclone second end208 for a distance beyond the inner side 185 of the air inlet conduit129. As a result, the open outlet end 195 is axially spaced apart fromthe inner side 185 of the air inlet conduit 129. In operation, the openlength 224 of the dirt outlet 190 is thus much less than the overalllength 225 of the slot 191.

Depending upon the length of the insert member 20, the diameter of thecyclone chamber 154 and the diameter of the passage 192, the top side233 of the insert member 230 may contact the cyclone outlet passage 192and may brush against the screen 197 when the insert member 230 isremoved from the cyclone chamber when the cyclone front end 206 is movedto the open position (see for example FIGS. 37-38). In such anembodiment, the insert member 230 may thus help dislodge dirt and debrisfrom the screen 197 to facilitate cleaning thereof. To facilitate theremoval of the insert member 230 in such an embodiment, the insertmember may be flexible or bendable (e.g., it may be made of a resilientmaterial) and/or the outlet passage 192 may be tapered and or shorter.

As exemplified, if the insert member 230 extends past the cyclone inlet,then the cyclone outlet passage 192 can be tapered. The reduction inwidth of the passage 192 moving from the second end 176 to the first end280 may allow the insert member 230 to be more easily withdrawn from thedirt outlet slot 191.

Optionally, the insert 230 may be flexible or bendable. As the front end206 is opened, the insert member 230 may contact the cyclone outletpassage 192 and press on the screen 197. As shown in FIGS. 37-38, insertmember 230 can flex in response to pressing against the outlet passage192 to allow the insert member 230 to be removed without damaging ordisplacing the outlet passage 192, while still assisting in cleaning thescreen 197.

In the example shown in FIGS. 35-38, the insert member 230 has agenerally triangular shape. The triangular shape of the insert member230 may support the insert member 230 and prevent flexing or bending inresponse to air flow in the cyclone chamber 154.

Alternately, other shapes of insert member 230 may be used. Referring toFIGS. 39-41, shown therein is another example of a cyclone 152 with arectangular insert member 230. The rectangular insert member 230 shownin FIGS. 39-41 may occupy less space allowing for increased capacity inthe dirt collection chamber 156.

As exemplified in FIGS. 42-44, in some embodiments the cyclone air inlet184 may terminate at a cyclone inlet port 187 formed in the sidewall 202of the cyclone chamber 154. In the example illustrated, the cycloneinlet port 187 is the terminal end of a tangential inlet and is anopening formed in the longitudinally extending sidewall 202. The cycloneair inlet 184 extends from a cyclone air inlet upstream end 310 to acyclone air inlet downstream end 312. The cyclone air inlet downstreamend 312 may be oriented to direct air substantially tangentially to theinner surface of sidewall 202.

In the illustrated example of FIGS. 42-44, cyclone air inlet 184 isformed as a curved passage 315 extending from a cyclone air inletupstream end 310 to a cyclone air inlet downstream end 312. The curvedpassage 315 may provide a gradual change of direction for the airpassing through the cyclone air inlet 184, which may reduce backpressurethrough the cyclone air inlet 184.

The cyclone air inlet 184 has an inlet width that extends between afirst inlet side 179 and a second inlet side 185. In the exampleillustrated, the first inlet side 179 and second inlet side 185 arespaced apart in a longitudinal axial direction generally parallel to thecyclone axis of rotation 204. The second inlet side 185, or downstreaminlet side, is positioned closer to the cyclone second end 208 than thefirst inlet side 179.

As exemplified, where the cyclone air inlet 184 terminates at a port 187in the cyclone chamber sidewall 202 such as exemplified in FIGS. 42-44,the first end 208 of the passage 192 may be located at the second inletside 185 or, alternately, it may be located axially inwardly of thesecond side 185 of the tangential air inlet 184 (i.e., towards cyclonesecond end 208), for example, 0.01, 0.05, 0.1 or 0.125 inches inwardlyof second inlet side 185.

In alternate embodiments, the first end 208 of the cyclone outletpassage 192 may extend to a position at or adjacent (e.g., within 0.01,0.05, 0.1 or 0.125 inches) of the first end 206 of the cyclone chamber154. For example, the passage first end 280 may terminate at about0.01-0.75 inches or about 0.05-0.375 inches from the cyclone first end206 in some embodiments. In such a case, the portion of cyclone outletpassage that is axially co-extensive with port 187 may be solid.

As exemplified in FIGS. 48-49, in some embodiments the cyclone 152 mayinclude a plurality of axially extending dirt outlet 190 ₁, 190 ₂, and190 ₃. This may allow the dirt outlets to intersect the air flow paththrough the cyclone chamber 154 at different locations, which may exposethe dirt outlets 190 ₁, 190 ₂, and 190 ₃ to dirt particles having awider range of residency time and particle velocities in the cyclonicflow.

Each of dirt outlets 190 ₁, 190 ₂, and 190 ₃ may be the same ordifferent. Each dirt outlet 190 ₁, 190 ₂, and 190 ₃ may be of any designdiscussed herein.

In the example illustrated in FIGS. 48 and 49, the cyclone 152 omits andinsert member 230 and a section 203 of the cyclone chamber sidewall 202extends to the dirt outlets 190 ₁, 190 ₂, and 190 ₃, similar to theembodiment of FIGS. 45-47, so that the dirt outlets 190 ₁, 190 ₂, and190 ₃ can be positioned proximate the downstream end of the air inlet184. Alternately, an insert member may be used to define the extent ofthe dirt outlets 190 ₁, 190 ₂, and 190 ₃. Alternately, the dirt outlets190 ₁, 190 ₂, and 190 ₃ may extend to the front end of cyclone 152.

In the example shown in FIGS. 48-49, each dirt outlet 190 ₁, 190 ₂, and190 ₃ connects the cyclone chamber 154 to a separate dirt collectionchamber 156 ₁, 156 ₂, and 156 ₃. This may reduce the amount of the airflow which diverts into each dirt collection chamber 156, which in turnmay reduce the re-entrainment of collected dirt that can result fromsuch divergence.

Alternately, the plurality of dirt outlets 190 may be connected to asingle dirt collection chamber 156. This may provide an increased dirtcollection volume and ensure that the entire dirt collection volume canbe used instead of having the empty the dirt collection chambers 156 ₁,156 ₂, and 156 ₃ when one becomes filled.

Cyclone Air Outlet

Embodiments herein relate to an improved cyclonic air outlet. Thefeatures in this section may be used by themselves in any surfacecleaning apparatus or in any combination or sub-combination with anyother feature or features described herein.

As exemplified in FIG. 2, cyclone chamber outlet passage 192 may haveany shape that can provide an outlet passage for air exiting cyclonechamber 154. Cyclone chamber outlet passage 192 may extendlongitudinally from a passage second end 276 at cyclone second end 208towards cyclone first end 206 (e.g. in parallel with cyclonelongitudinal axis 204) to a passage first end 280. As shown, cyclonechamber outlet passage 192 may be spaced apart from cyclone sidewall 202to define a surrounding annular region between cyclone chamber outletpassage 192 and cyclone sidewall 202 that promotes cyclonic air flowthrough cyclone chamber 154.

In the illustrated embodiment, cyclone chamber outlet passage 192 has atransverse width 288 (e.g. diameter) that is substantially constant(e.g. varies by less than 10%) between passage first end 280 and passagesecond end 276. Depending on the size and shape of cyclone sidewall 202,this may provide the air flow path through cyclone chamber 154 with arelatively constant cross-sectional area.

In accordance with this feature, as exemplified in FIG. 22, cyclonechamber outlet passage 192 may have a transverse width 288 thatincreases between passage first end 280 and passage second end 276towards passage second end 276. In other words, cyclone chamber outletpassage 192 may taper in transverse width 288 towards passage first end280. Depending on the size and shape of cyclone sidewall 202, this mayprovide the air flow path through cyclone chamber 154 with a shrinkingcross-sectional area as the air flow travels from cyclone air inlet 184towards cyclone second end 208. As a result of the inverse relationshipbetween cross-sectional area and velocity, the progressive reduction incross-sectional flow area may increase the flow velocity towards cyclonesecond end 208. This may mitigate a loss of velocity and cyclonicdegradation that may develop towards cyclone second end 208 particularlywhen operating at low flow rates (e.g. in a lower power mode).Consequently, the tapered cyclone chamber outlet passage 192 may promotegreater overall separation efficiency for cyclone 152.

As shown, transverse width 288 may increase continuously between passagefirst end 280 and passage second end 276. In some embodiments,transverse width 288 may increase by at least 10% (e.g. by 10% to 200%,25% to 175%, 40% to 125% or 60% to 90%) between passage first end 280and passage second end 276. In the illustrated embodiment, transversewidth 288 increases by about 125% between passage first end 280 andpassage second end 276.

As exemplified, passage first end 280 may be solid and may have an axiallength that is at least as long as, or longer than, the axial inwardextent of the cyclone air inlet. Accordingly, air that enters thecyclone chamber may not directly enter the outlet passage 192, as thefirst end 280 is solid.

Although many of the figures illustrate concepts and embodiments appliedto an exemplary handvac, all of the embodiments described herein applyequally to other surface cleaning apparatus (e.g. upright vacuums,canister vacuums, etc.). Further, although many of the figuresillustrate a uniflow cyclone that is horizontally oriented, allembodiments disclosed here are also applicable to other cycloneconfigurations and orientations. As an example, FIGS. 24-25 show anupright vacuum 100 having a cyclonic air treatment member 116 with aninverted cyclone 152. As shown, cyclone 152 has a central longitudinalaxis 204 that is vertically oriented, a plurality of dirt outlet regions190 (which may have any configuration disclosed in any embodimentherein), a cyclone chamber air outlet passage 192 (which may have anyconfiguration disclosed in any embodiment here), and both the cycloneair inlet 184 and outlet 188 are located at cyclone first end 206.

Reference is now made to FIGS. 26-27. In some embodiments, a dirt outletregion 190 may provide an entryway to a dirt outlet passage 292 leadingto dirt collection chamber 156. This may be the case for the only dirtoutlet region 190 of a cyclone 152 as shown, or for one or more (or all)dirt outlet regions 190 of a cyclone 152 having many dirt outlet regions190 (e.g. as in any embodiment disclosed herein having two or more dirtoutlets 190). An advantage of providing a dirt outlet passage 292between a dirt outlet region 190 and the dirt collection chamber 156 isthat it may reduce the amount of air flow that diverts from the cyclonechamber 154 into the dirt collection chamber 156. Diverted air flow canproduce a pressure drop in the air flow through cyclone 152, which mayresult in less suction and possibly lower dirt separation efficiency allelse being equal. By mitigating pressure drops, a smaller, lighter, lessexpensive suction motor may be used to achieve the same suction, orgreater suction may be achieved with the same suction motor. Further,diverted air flow may disturb dirt that has collected in dirt collectionchamber 156, which may lead to that dirt re-emerging into the cyclonechamber 154 through the dirt outlet region 190. A dirt outlet passage292 may help to mitigate dirt collected in dirt collection chamber 156from returning to cyclone chamber 154.

Dirt outlet passage 292 has a length 296 extending from dirt outletregion 190 to passage outlet 304. Passage outlet 304 may be locatedinside dirt collection chamber 156 as shown, or may be formed in asidewall of dirt collection chamber 156 (e.g., the outlet end may be aport provided in a sidewall of the dirt collection chamber 156). Passageoutlet 304 may have any passage length 296 suitable for directing dirtexiting from cyclone chamber 154 at a dirt outlet region 190 to dirtcollection chamber 156. Preferably, passage length 296 is greater than athickness of cyclone chamber sidewall 202. For example, passage length296 may be greater than 5 mm (e.g. between 5 mm and 300 mm, 25-250 mm,50-200 mm or 75-150 mm). A passage length 296 closer to 5 mm may beappropriate where, for example, cyclone chamber 154 and dirt collectionchamber 156 share a common dividing wall 202. A passage length muchgreater than 5 mm (e.g. 50 mm or more) may be appropriate where, forexample, cyclone chamber 154 and dirt collection chamber 156 are spacedapart.

Dirt outlet passage 292 may extend in any direction from dirt outletregion 190 towards dirt collection chamber 156. In some embodiments,dirt outlet passage 292 is oriented tangential to cyclone chamber 154.FIG. 26 shows an example in which dirt outlet passage 292 is orientedtangential cyclone chamber 154 in alignment with the direction ofcyclone air flow path 212 where cyclone air flow path 212 crosses dirtoutlet region 190. An advantage of this design is that dirt outletpassage 292 may be oriented in the same direction as the direction ofdirt particles at dirt outlet 190. This may increase particle separationefficiency by reducing the number of dirt particles which cross overdirt outlet region 190 without exiting cyclone chamber 154. However,such tangential alignment may also lead to a somewhat greater amount ofthe air flow diverting from cyclone chamber 154 into dirt collectionchamber 156. FIG. 27 shows an example in which dirt outlet passage 292is oriented tangential to cyclone chamber 154 but extending in adirection opposed to the direction of cyclone air flow path 212 wherecyclone air flow path 212 crosses dirt outlet 190. An advantage of thisdesign is that it may reduce the amount of air that diverts from cyclonechamber 154 to dirt collection chamber 156, although a somewhat greaternumber of dirt particles may pass over dirt outlet 190 without exiting.

While the above description provides examples of the embodiments, itwill be appreciated that some features and/or functions of the describedembodiments are susceptible to modification without departing from thespirit and principles of operation of the described embodiments.Accordingly, what has been described above has been intended to beillustrative of the invention and non-limiting and it will be understoodby persons skilled in the art that other variants and modifications maybe made without departing from the scope of the invention as defined inthe claims appended hereto. The scope of the claims should not belimited by the preferred embodiments and examples, but should be giventhe broadest interpretation consistent with the description as a whole.

The invention claimed is:
 1. A vacuum cleaner comprising an air flowpath extending from a dirty air inlet to a clean air outlet with a firstcyclonic cleaning stage and a suction motor positioned in the air flowpath, the first cyclonic cleaning stage comprising a first cyclonechamber and a first dirt collection chamber external to the firstcyclone chamber, the first cyclone chamber having a cyclone first end,an opposed cyclone second end, a cyclone sidewall extending between thecyclone first end and the cyclone second end, a cyclone air inlet, acyclone air outlet provided at the cyclone second end, a cyclone dirtoutlet in communication with the first dirt collection chamber and acyclone longitudinal axis extending from the cyclone first end to thecyclone second end, wherein the dirt outlet comprises a plurality ofapertures, wherein the cyclone air outlet extends inwardly a firstdistance from the cyclone second end towards the cyclone first end, andwherein the cyclone sidewall extends angularly 360° around the cyclonelongitudinal axis and a portion of the cyclone sidewall having theplurality of apertures extends angularly only part way around thecyclone longitudinal axis and wherein the portion of the sidewallextends inwardly into the cyclone chamber a distance that is up to aboutthe first distance.
 2. The vacuum cleaner of claim 1 wherein theplurality of apertures comprises more than 10 apertures.
 3. The vacuumcleaner of claim 1 wherein the plurality of apertures comprises morethan 20 apertures.
 4. The vacuum cleaner of claim 2 wherein theapertures have a width of 0.10 inches to 0.20 inches.
 5. The vacuumcleaner of claim 2 wherein the apertures have a width of 0.010 inches to0.10 inches.
 6. The vacuum cleaner of claim 1 wherein the apertures areprovided at a cyclone air outlet end of the first cyclone chamber. 7.The vacuum cleaner of claim 6 wherein the cyclone air outlet end is thecyclone second end and the cyclone air inlet is provided at the cyclonefirst end.
 8. The vacuum cleaner of claim 1 wherein the vacuum cleaneris a hand vacuum cleaner having an upper end and a lower end, the upperend has the dirty air inlet and, when the hand vacuum cleaner isoriented with the upper end above the lower end, the apertures areprovided in a lower portion of the cyclone sidewall.
 9. The surf vacuumcleaner ace cleaning apparatus of claim 8 wherein the cyclonic cleaningstage comprises a stationary portion and an openable portion, theopenable portion is part of the lower end of the hand vacuum cleaner andcomprises a portion of the cyclone sidewall and the openable portion ismoveably mounted by a mount between a closed position in which the firstcyclone chamber and the first dirt collection chamber are closed and anopen position in which the first cyclone chamber and the first dirtcollection chamber are open and the apertures are provided in theopenable portion.
 10. The vacuum cleaner of claim 8 wherein, when thehand vacuum cleaner is oriented with the upper end above the lower end,the first dirt collection chamber underlies the first cyclone chamber.11. The vacuum cleaner of claim 1 wherein the first cyclone chamber hasa first lateral side that extends radially outwardly from the cyclonelongitudinal axis in a first direction and a second lateral side thatextends radially outwardly from the cyclone longitudinal axis in asecond direction that is opposed to the first direction and theapertures are provided only on the first lateral side of the firstcyclone chamber.
 12. The vacuum cleaner of claim 1 further comprising asecond cyclonic cleaning stage downstream from the first cycloniccleaning stage, the second cyclonic cleaning stage having a dirtcollection region wherein, when the hand vacuum cleaner is oriented withthe upper end above the lower end, the first dirt collection chamber andthe dirt collection region each underlie the first cyclone chamber. 13.The vacuum cleaner of claim 12 wherein the second cyclonic cleaningstage comprises a second cyclone chamber and a second dirt collectionchamber external to the second cyclone chamber and the second dirtcollection chamber comprises the dirt collection region.
 14. The vacuumcleaner of claim 13 wherein the first cyclone chamber has a firstlateral side that extends radially outwardly from the cyclonelongitudinal axis in a first direction and a second lateral side thatextends radially outwardly from the cyclone longitudinal axis in asecond direction that is opposed to the first direction and theapertures are provided only on the first lateral side of the firstcyclone chamber, the first dirt collection chamber is located on thefirst lateral side and the dirt collection region is located on thesecond lateral side.
 15. A vacuum cleaner comprising: (a) a front endhaving a dirty air inlet, a rear end, and first and second laterallyopposed sides, each laterally opposed side extends in a forward/rearwarddirection; (b) an air flow path extending from a dirty air inletprovided at the front end to a clean air outlet with a suction motorpositioned in the air flow path; (c) a first air treatment stagepositioned in the air flow path downstream from the dirty air inlet, thefirst air treatment stage comprising a first air treatment chamber and afirst dirt collection chamber external to the first air treatmentchamber; and, (d) a second air treatment stage positioned in the airflow path downstream from the first air treatment stage and rearward ofthe first air treatment chamber, the second air treatment stagecomprising a second air treatment chamber and a second dirt collectionchamber external to the second air treatment chamber, wherein the firstdirt collection chamber is provided on the first lateral side andunderlies the first air treatment chamber and the second dirt collectionchamber is provided on the second lateral side and underlies the firstair treatment chamber, and wherein the first dirt collection chamber andthe second dirt collection chamber are emptyable concurrently.
 16. Thevacuum cleaner of claim 15 wherein the first air treatment chamber has adirt outlet in communication with the first dirt collection chamber andthe dirt outlet comprises a plurality of apertures.
 17. The vacuumcleaner of claim 16 wherein the plurality of apertures comprises morethan 10 apertures.
 18. The vacuum cleaner of claim 16 wherein theplurality of apertures comprises more than 20 apertures.
 19. The vacuumcleaner of claim 17 wherein the apertures have a width of 0.10 inches to0.20 inches.
 20. The vacuum cleaner of claim 17 wherein the apertureshave a width of 0.010 inches to 0.10 inches.